Smoking substitute apparatus

ABSTRACT

A smoking substitute apparatus comprises: an air inlet; an outlet; an aerosol generator for generating an aerosol from an aerosol precursor for inhalation by a user, the aerosol generator comprising a heating element; an air flow path between the air inlet and the outlet for conveying the aerosol to the user. An upstream portion of the air flow path is disposed between the air inlet and the aerosol generator. The upstream portion is defined at least in part by an inner wall of the apparatus, the inner wall being formed from plastics material by moulding. Electrical connectors are provided for electrically connecting the heating element to a power source. The electrical connectors are at least partially moulded into, and extend along, the inner wall of the upstream portion of the air flow path, thereby increasing the available cross sectional area for air flow and reducing the flow velocity in the upstream portion.

CROSS REFERENCE TO RELATED APPLICATIONS

The present disclosure claims the benefit of priority from the following applications, the entire contents of which are hereby incorporated by reference:

[ME ref: 7624570; Nerudia ref: P01221—referred to herein as Development A]

European patent application no. 20170111.7 filed 17 Apr. 2020

[ME ref: 7623218; Nerudia ref: P01205— referred to herein as Development B]

European patent application no. 20170107.5 filed 17 Apr. 2020

[ME ref: 7628191; Nerudia ref: P01210— referred to herein as Development C]

European patent application no. 20170114.1 filed 17 Apr. 2020

FIELD OF THE INVENTION

The present invention relates to a smoking substitute apparatus and, in particular, a smoking substitute apparatus that is able to deliver nicotine to a user in an effective manner.

BACKGROUND

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is thought that a significant amount of the potentially harmful substances are generated through the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.

Low temperature combustion of organic material such as tobacco is known to produce tar and other potentially harmful by-products. There have been proposed various smoking substitute systems in which the conventional smoking of tobacco is avoided.

Such smoking substitute systems can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

Known smoking substitute systems include electronic systems that permit a user to simulate the act of smoking by producing an aerosol (also referred to as a “vapour”) that is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or a flavourant without, or with fewer of, the health risks associated with conventional smoking.

In general, smoking substitute systems are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar, or improved, experience and satisfaction to those experienced with conventional smoking and with combustible tobacco products.

The use of smoking substitute systems has grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit tobacco smoking. There are a number of different categories of smoking substitute systems, each utilising a different smoking substitute approach. Some smoking substitute systems are designed to resemble a conventional cigarette and are cylindrical in form with a mouthpiece at one end. Other smoking substitute devices do not generally resemble a cigarette (for example, the smoking substitute device may have a generally box-like form, in whole or in part).

One approach is the so-called “vaping” approach, in which a vaporisable liquid, or an aerosol former, sometimes typically referred to herein as “e-liquid”, is heated by a heating device (sometimes referred to herein as an electronic cigarette or “e-cigarette” device) to produce an aerosol vapour which is inhaled by a user. The e-liquid typically includes a base liquid, nicotine and may include a flavourant. The resulting vapour therefore also typically contains nicotine and/or a flavourant. The base liquid may include propylene glycol and/or vegetable glycerine.

A typical e-cigarette device includes a mouthpiece, a power source (typically a battery), a tank for containing e-liquid and a heating device. In use, electrical energy is supplied from the power source to the heating device, which heats the e-liquid to produce an aerosol (or “vapour”) which is inhaled by a user through the mouthpiece.

E-cigarettes can be configured in a variety of ways. For example, there are “closed system” vaping smoking substitute systems, which typically have a sealed tank and heating element. The tank is pre-filled with e-liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute systems include a main body which includes the power source, wherein the main body is configured to be physically and electrically couplable to a consumable including the tank and the heating element. In this way, when the tank of a consumable has been emptied of e-liquid, that consumable is removed from the main body and disposed of. The main body can then be reused by connecting it to a new, replacement, consumable. Another subset of closed system vaping smoking substitute systems are completely disposable, and intended for one-use only.

There are also “open system” vaping smoking substitute systems which typically have a tank that is configured to be refilled by a user. In this way the entire device can be used multiple times.

An example vaping smoking substitute system is the Myblu™ e-cigarette. The Myblu™ e-cigarette is a closed system which includes a main body and a consumable. The main body and consumable are physically and electrically coupled together by pushing the consumable into the main body. The main body includes a rechargeable battery. The consumable includes a mouthpiece and a sealed tank which contains e-liquid. The consumable further includes a heater, which for this device is a heating filament coiled around a portion of a wick. The wick is partially immersed in the e-liquid, and conveys e-liquid from the tank to the heating filament. The system is controlled by a microprocessor on board the main body. The system includes a sensor for detecting when a user is inhaling through the mouthpiece, the microprocessor then activating the device in response. When the system is activated, electrical energy is supplied from the power source to the heating device, which heats e-liquid from the tank to produce a vapour which is inhaled by a user through the mouthpiece.

SUMMARY OF THE INVENTION

For a smoking substitute system it is desirable to deliver nicotine into the user's lungs, where it can be absorbed into the bloodstream. However, the present disclosure is based in part on a realisation that some prior art smoking substitute systems, such delivery of nicotine is not efficient. In some prior art systems, the aerosol droplets have a size distribution that is not suitable for delivering nicotine to the lungs. Aerosol droplets of a large particle size tend to be deposited in the mouth and/or upper respiratory tract. Aerosol particles of a small (e.g. sub-micron) particle size can be inhaled into the lungs but may be exhaled without delivering nicotine to the lungs. As a result the user would require drawing a longer puff, more puffs, or vaporising e-liquid with a higher nicotine concentration in order to achieve the desired experience.

It is of interest to change the aerosol particle size to be inhaled compared with known smoking substitute systems, in part to take advantage over the phenomena reported above concerning the effect of aerosol particle size on the deposition location within the user's respiratory system.

The present disclosure (Development A) has been devised in the light of the above considerations.

In a general aspect of Development A, the present invention provides one or more electrical connectors at least partially moulded into, and extending along, an inner wall of an upstream portion of an air flow path, upstream of an aerosol generator. It is considered that this approach can provide an increased cross sectional diameter for the air flow upstream of the aerosol generator and promote the formation of an aerosol with advantageous particle size characteristics.

According to a first preferred aspect of Development A, there is provided a smoking substitute apparatus comprising:

an air inlet;

an outlet;

an aerosol generator for generating an aerosol from an aerosol precursor for inhalation by a user, the aerosol generator comprising a heating element;

an air flow path between the air inlet and the outlet for conveying the aerosol to the user;

an upstream portion of the air flow path being disposed between the air inlet and the aerosol generator, the upstream portion being defined at least in part by an inner wall of the apparatus, the inner wall being formed from plastics material by moulding;

one or more electrical connectors for electrically connecting the heating element to a power source;

wherein the one or more electrical connectors are at least partially moulded into, and extend along, the inner wall of the upstream portion of the air flow path.

According to a second preferred aspect of Development A, there is provided a smoking substitute system comprising a smoking substitute apparatus according to the first aspect and a main body, the main body comprising a power source, the smoking substitute apparatus and the main body being engageable together to form the smoking substitute system.

According to a third preferred aspect of Development A, there is provided a method of operating a smoking substitute apparatus according to the first aspect or a smoking substitute system according to the second aspect in which air is drawn through the apparatus at an air flow rate in the range 1.3-2.0 L/min and the aerosol generator operated to produce an aerosol with Dv50 in the range 2-5 μm.

Based on the insight and research of the present inventors, it is considered that the air flow conditions at the aerosol generator have a significant effect on the particle size characteristics of the aerosol. In particular, it is considered that high velocity and/or turbulent air flow at the aerosol generator will tend to promote the formation of an aerosol with relatively small particle size.

By using embodiments of the present invention, it is considered that the flow conditions in the upstream portion of the air flow path can have relatively low velocity and preferably relatively low (or no) turbulence for a typical inhalation rate. In order to deliver power to the heating element, it is convenient to have the electrical connectors provided along the upstream portion of the air flow path. However, by ensuring that these electrical connectors are at least partially moulded into the inner wall of an upstream portion of the air flow path, there is provided a greater cross sectional area for the air to flow through the apparatus to the aerosol generator than would otherwise be the case. Having a greater cross sectional area upstream of the aerosol generator results in a reduced average air flow velocity for the same air flow rate. As explained (and shown) in more detail below, it is considered that this can result in slower cooling of the vapour emitted by the aerosol generator and can in turn result in a larger average particle size, and preferably a more uniform particle size distribution, for the generated aerosol.

Considering a length direction of the electrical connector, the length direction may be substantially parallel to the air flow direction along the air flow path in the upstream portion. Along the length of the electrical connector, some parts of the length may be moulded, or partially moulded, into the inner wall of the upstream portion of the air flow path. Other parts of the electrical connector, for example one of more parts between the parts of the length that are moulded into the inner wall, may simply abut the inner wall by virtue of the moulded parts.

The electrical connector may have a strip shape, with the length of the strip corresponding to the length direction mentioned above, a width direction corresponding to a circumferential direction of the upstream portion of the air flow path, perpendicular to the length direction, and a depth direction corresponding to a radial direction of the upstream portion of the air flow path, perpendicular to both the length direction and the circumferential direction.

The width of the electrical connector may vary along its length. In particular, the electrical connector may have wide portions at which the electrical connectors is moulded or partially moulded to the inner wall of the upstream portion. There may be narrow portions between said wide portions. The narrow portions may abut the inner wall and may not be moulded into the inner wall. The wide portions may have a generally circular region. The inner wall may be moulded into an aperture formed in the wide portions.

An aspect ratio of the electrical connector is typically such that the depth is significantly smaller than the width. For example, the aspect ratio (defined as width/depth) is preferably not less than 4.

The electrical connector has a main surface directed to face the air flow in the upstream portion. In some embodiments, there is no part of the inner wall that is interposed between the main surface and the air flow in the upstream portion.

The electrical connector may be partially moulded into the inner wall along the length of the electrical connector in the upstream portion of the air flow path. For example, considering the proportion of the depth of the electrical connector that is moulded into the inner wall, this proportion may be at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80% or at least 90%. The remainder of the depth of the electrical connector (i.e. at most 70%, at most 60%, at most 50%, at most 40%, at most 30%, at most 20%, at most 10%, respectively) may therefore project from the inner wall into the upstream portion of the air flow path.

Alternatively, the electrical connector may be fully moulded into the inner wall of the upstream portion of the air flow path.

Similar considerations apply independently to each electrical connector, where there are two or more electrical connectors present.

There now follows a disclosure of various optional features. These are intended to be applicable to Development A, disclosed above, and may also be applied in any combination (unless the context demands otherwise) to any aspect, embodiment or optional feature set out with respect to Development B and/or Development C.

The smoking substitute apparatus may be comprised by or within a cartridge configured for engagement with the main body, the cartridge and main body together forming a smoking substitute system. The smoking substitute apparatus may be removably engageable with the main body (which may also be referred to herein as the base unit).

The smoking substitute apparatus may be in the form of a consumable. The consumable may be configured for engagement with a main body. When the consumable is engaged with the main body, the combination of the consumable and the main body may form a smoking substitute system such as a closed smoking substitute system. For example, the consumable may comprise components of the system that are disposable, and the main body may comprise non-disposable or non-consumable components (e.g. power supply, controller, sensor, etc.) that facilitate the generation and/or delivery of aerosol by the consumable. In such an embodiment, the aerosol precursor (e.g. e-liquid) may be replenished by replacing a used consumable with an unused consumable.

Alternatively, the smoking substitute apparatus may be a non-consumable apparatus (e.g. that is in the form of an open smoking substitute system). In such embodiments an aerosol former (e.g. e-liquid) of the system may be replenished by re-filling, e.g. a reservoir of the smoking substitute apparatus, with the aerosol precursor (rather than replacing a consumable component of the apparatus).

In light of this, it should be appreciated that some of the features described herein as being part of the smoking substitute apparatus may alternatively form part of a main body for engagement with the smoking substitute apparatus. This may be the case in particular when the smoking substitute apparatus is in the form of a consumable.

Where the smoking substitute apparatus is in the form of a consumable, the main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess of the main body, such that there is an interference fit between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting, or the like.

Thus, the smoking substitute apparatus may comprise one or more engagement portions for engaging with a main body. In this way, one end of the smoking substitute apparatus may be coupled with the main body, whilst an opposing end of the smoking substitute apparatus may define a mouthpiece of the smoking substitute system.

The smoking substitute apparatus may comprise a reservoir configured to store an aerosol precursor, such as an e-liquid. The e-liquid may, for example, comprise a base liquid. The e-liquid may further comprise nicotine. The base liquid may include propylene glycol and/or vegetable glycerine. The e-liquid may be substantially flavourless. That is, the e-liquid may not contain any deliberately added additional flavourant and may consist solely of a base liquid of propylene glycol and/or vegetable glycerine and nicotine.

The reservoir may be in the form of a tank. At least a portion of the tank may be light-transmissive. For example, the tank may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. A housing of the smoking substitute apparatus may comprise a corresponding aperture (or slot) or window that may be aligned with a light-transmissive portion (e.g. window) of the tank. The reservoir may be referred to as a “clearomizer” if it includes a window, or a “cartomizer” if it does not.

The outlet may be at a mouthpiece of the smoking substitute apparatus. In this respect, a user may draw fluid (e.g. air) into and through the passage by inhaling at the outlet (i.e. using the mouthpiece). The passage may be at least partially defined by the tank. The tank may substantially (or fully) define the passage, for at least a part of the length of the passage. In this respect, the tank may surround the passage, e.g. in an annular arrangement around the passage.

The vaporisation chamber may be arranged to be in fluid communication with the inlet and outlet of the passage. The vaporisation chamber may be an enlarged portion of the passage. In this respect, the air as drawn in by the user may entrain the generated vapour in a flow away from heater. The entrained vapour may form an aerosol in the vaporisation chamber, or it may form the aerosol further downstream along the passage. The vaporisation chamber may be at least partially defined by the tank. The tank may substantially (or fully) define the vaporisation chamber, and thus may form the enclosure. In this respect, the tank may surround the vaporisation chamber, e.g. in an annular arrangement around the vaporisation chamber.

In use, the user may puff on a mouthpiece of the smoking substitute apparatus, i.e. draw on the smoking substitute apparatus by inhaling, to draw in an air stream therethrough. A part of the air flow which bypasses the vaporisation chamber (dilution air flow) may combine with the other part of the air flow (main air flow) for diluting the aerosol contained therein. The dilution air flow may be directly inhaled by the user without passing through the passage of the smoking substitute apparatus.

As a user puffs on the mouthpiece, vaporised e-liquid entrained in the passing air flow may be drawn towards the outlet of the passage. The vapour may cool, and thereby nucleate and/or condense along the passage to form a plurality of aerosol droplets, e.g. nicotine-containing aerosol droplets. A portion of these aerosol droplets may be delivered to and be absorbed at a target delivery site, e.g. a user's lung, whilst a portion of the aerosol droplets may instead adhere onto other parts of the user's respiratory tract, e.g. the user's oral cavity and/or throat. Typically, in some known smoking substitute apparatuses, the aerosol droplets as measured at the outlet of the passage, e.g. at the mouthpiece, may have a droplet size, d₅₀, of less than 1 μm.

In some embodiments of the invention, the d₅₀ particle size of the aerosol particles is preferably at least 1 μm, more preferably at least 2 μm. Typically, the d₅₀ particle size is not more than 10 μm, preferably not more than 9 μm, not more than 8 μm, not more than 7 μm, not more than 6 μm, not more than 5 μm, not more than 4 μm or not more than 3 μm. It is considered that providing aerosol particle sizes in such ranges permits improved interaction between the aerosol particles and the user's lungs.

The particle droplet size, d₅₀, of an aerosol may be measured by a laser diffraction technique. For example, the stream of aerosol output from the outlet of the passage may be drawn through a Malvern Spraytec laser diffraction system, where the intensity and pattern of scattered laser light are analysed to calculate the size and size distribution of aerosol droplets. As will be readily understood, the particle size distribution may be expressed in terms of d₁₀, d₅₀ and d₉₀, for example. Considering a cumulative plot of the volume of the particles measured by the laser diffraction technique, the d₁₀ particle size is the particle size below which 10% by volume of the sample lies. The d₅₀ particle size is the particle size below which 50% by volume of the sample lies. The d₅₀ particle size is the particle size below which 90% by volume of the sample lies. Unless otherwise indicated herein, the particle size measurements are volume-based particle size measurements, rather than number-based or mass-based particle size measurements.

The spread of particle size may be expressed in terms of the span, which is defined as (d₉₀−d₁₀)/d₅₀. Typically, the span is not more than 20, preferably not more than 10, preferably not more than 8, preferably not more than 4, preferably not more than 2, preferably not more than 1, or not more than 0.5.

The smoking substitute apparatus (or main body engaged with the smoking substitute apparatus) may comprise a power source. The power source may be electrically connected (or connectable) to a heater of the smoking substitute apparatus (e.g. when the smoking substitute apparatus is engaged with the main body). The power source may be a battery (e.g. a rechargeable battery). A connector in the form of e.g. a USB port may be provided for recharging this battery.

When the smoking substitute apparatus is in the form of a consumable, the smoking substitute apparatus may comprise an electrical interface for interfacing with a corresponding electrical interface of the main body. One or both of the electrical interfaces may include one or more electrical contacts. Thus, when the main body is engaged with the consumable, the electrical interface of the main body may be configured to transfer electrical power from the power source to a heater of the consumable via the electrical interface of the consumable.

The electrical interface of the smoking substitute apparatus may also be used to identify the smoking substitute apparatus (in the form of a consumable) from a list of known types. For example, the consumable may have a certain concentration of nicotine and the electrical interface may be used to identify this. The electrical interface may additionally or alternatively be used to identify when a consumable is connected to the main body.

Again, where the smoking substitute apparatus is in the form of a consumable, the main body may comprise an identification means, which may, for example, be in the form of an RFID reader, a barcode or QR code reader. This identification means may be able to identify a characteristic (e.g. a type) of a consumable engaged with the main body. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the identification means.

The smoking substitute apparatus or main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater of the smoking substitute apparatus (e.g. via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The main body or smoking substitute apparatus may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g. via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g. WiFi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

A puff sensor may be provided that is configured to detect a puff (i.e. inhalation from a user). The puff sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e. puffing or not puffing). The puff sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. That is, the controller may control power supply to the heater of the consumable in response to a puff detection by the sensor. The control may be in the form of activation of the heater in response to a detected puff. That is, the smoking substitute apparatus may be configured to be activated when a puff is detected by the puff sensor. When the smoking substitute apparatus is in the form of a consumable, the puff sensor may be provided in the consumable or alternatively may be provided in the main body.

The term “flavourant” is used to describe a compound or combination of compounds that provide flavour and/or aroma. For example, the flavourant may be configured to interact with a sensory receptor of a user (such as an olfactory or taste receptor). The flavourant may include one or more volatile substances.

The flavourant may be provided in solid or liquid form. The flavourant may be natural or synthetic. For example, the flavourant may include menthol, liquorice, chocolate, fruit flavour (including e.g. citrus, cherry etc.), vanilla, spice (e.g. ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed or may be provided in isolated locations and/or varying concentrations.

The present inventors consider that a flow rate of 1.3 L min⁻¹ is towards the lower end of a typical user expectation of flow rate through a conventional cigarette and therefore through a user-acceptable smoking substitute apparatus. The present inventors further consider that a flow rate of 2.0 L min⁻¹ is towards the higher end of a typical user expectation of flow rate through a conventional cigarette and therefore through a user-acceptable smoking substitute apparatus. Embodiments of the present invention therefore provide an aerosol with advantageous particle size characteristics across a range of flow rates of air through the apparatus.

The aerosol may have a Dv50 of at least 1.1 μm, at least 1.2 μm, at least 1.3 μm, at least 1.4 μm, at least 1.5 μm, at least 1.6 μm, at least 1.7 μm, at least 1.8 μm, at least 1.9 μm or at least 2.0 μm.

The aerosol may have a Dv50 of not more than 4.9 μm, not more than 4.8 μm, not more than 4.7 μm, not more than 4.6 μm, not more than 4.5 μm, not more than 4.4 μm, not more than 4.3 μm, not more than 4.2 μm, not more than 4.1 μm, not more than 4.0 μm, not more than 3.9 μm, not more than 3.8 μm, not more than 3.7 μm, not more than 3.6 μm, not more than 3.5 μm, not more than 3.4 μm, not more than 3.3 μm, not more than 3.2 μm, not more than 3.1 μm or not more than 3.0 μm.

A particularly preferred range for Dv50 of the aerosol is in the range 2-3 μm.

The air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber is in the range 0-1.3 ms⁻¹. The average magnitude velocity of air may be calculated based on knowledge of the geometry of the vaporisation chamber and the flow rate.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber may be at most 1.2 ms⁻¹, at most 1.1 ms⁻¹, at most 1.0 ms⁻¹, at most 0.9 ms⁻¹, at most 0.8 ms⁻¹, at most 0.7 ms⁻¹ or at most 0.6 ms⁻¹.

The air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber is in the range 0-1.3 ms⁻¹. The average magnitude velocity of air may be calculated based on knowledge of the geometry of the vaporisation chamber and the flow rate.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber may be at most 1.2 ms⁻¹, at most 1.1 ms⁻¹, at most 1.0 ms⁻¹, at most 0.9 ms⁻¹, at most 0.8 ms⁻¹, at most 0.7 ms⁻¹ or at most 0.6 ms⁻¹.

When the calculated average magnitude of velocity of air in the vaporisation chamber is in the ranges specified, it is considered that the resultant aerosol particle size is advantageously controlled to be in a desirable range. It is further considered that the configuration of the apparatus can be selected so that the average magnitude of velocity of air in the vaporisation chamber can be brought within the ranges specified, at the exemplary flow rate of 1.3 L min⁻¹ and/or the exemplary flow rate of 2.0 L min⁻¹.

The aerosol generator may comprise a vaporiser element loaded with aerosol precursor, the vaporiser element being heatable by a heater and presenting a vaporiser element surface to air in the vaporisation chamber. A vaporiser element region may be defined as a volume extending outwardly from the vaporiser element surface to a distance of 1 mm from the vaporiser element surface.

The air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region is in the range 0-1.2 ms⁻¹. The average magnitude of velocity of air in the vaporiser element region may be calculated using computational fluid dynamics.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region may be at most 1.1 ms⁻¹, at most 1.0 ms⁻¹, at most 0.9 ms⁻¹, at most 0.8 ms⁻¹, at most 0.7 ms⁻¹ or at most 0.6 ms⁻¹.

The air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region is in the range 0-1.2 ms⁻¹. The average magnitude of velocity of air in the vaporiser element region may be calculated using computational fluid dynamics.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region may be at most 1.1 ms⁻¹, at most 1.0 ms⁻¹, at most 0.9 ms⁻¹, at most 0.8 ms⁻¹, at most 0.7 ms⁻¹ or at most 0.6 ms⁻¹.

When the average magnitude of velocity of air in the vaporiser element region is in the ranges specified, it is considered that the resultant aerosol particle size is advantageously controlled to be in a desirable range. It is further considered that the velocity of air in the vaporiser element region is more relevant to the resultant particle size characteristics than consideration of the velocity in the vaporisation chamber as a whole. This is in view of the significant effect of the velocity of air in the vaporiser element region on the cooling of the vapour emitted from the vaporiser element surface.

Additionally or alternatively is it relevant to consider the maximum magnitude of velocity of air in the vaporiser element region.

Therefore, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region is in the range 0-2.0 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region may be at most 1.9 ms⁻¹, at most 1.8 ms⁻¹, at most 1.7 ms⁻¹, at most 1.6 ms⁻¹, at most 1.5 ms⁻¹, at most 1.4 ms⁻¹, at most 1.3 ms⁻¹ or at most 1.2 ms⁻¹.

The air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region is in the range 0-2.0 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region may be at most 1.9 ms⁻¹, at most 1.8 ms⁻¹, at most 1.7 ms⁻¹, at most 1.6 ms⁻¹, at most 1.5 ms⁻¹, at most 1.4 ms⁻¹, at most 1.3 ms⁻¹ or at most 1.2 ms⁻¹.

It is considered that configuring the apparatus in a manner to permit such control of velocity of the airflow at the vaporiser permits the generation of aerosols with particularly advantageous particle size characteristics, including Dv50 values.

Additionally or alternatively is it relevant to consider the turbulence intensity in the vaporiser chamber in view of the effect of turbulence on the particle size of the generated aerosol. For example, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the turbulence intensity in the vaporiser element region is not more than 1%.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the turbulence intensity in the vaporiser element region may be not more than 0.95%, not more than 0.9%, not more than 0.85%, not more than 0.8%, not more than 0.75%, not more than 0.7%, not more than 0.65% or not more than 0.6%.

It is considered that configuring the apparatus in a manner to permit such control of the turbulence intensity in the vaporiser element region permits the generation of aerosols with particularly advantageous particle size characteristics, including Dv50 values.

Following detailed investigations, the inventors consider, without wishing to be bound by theory, that the particle size characteristics of the generated aerosol may be determined by the cooling rate experienced by the vapour after emission from the vaporiser element (e.g. wick). In particular, it appears that imposing a relatively slow cooling rate on the vapour has the effect of generating aerosols with a relatively large particle size. The parameters discussed above (velocity and turbulence intensity) are considered to be mechanisms for implementing a particular cooling dynamic to the vapour.

More generally, it is considered that the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that a desired cooling rate is imposed on the vapour. The particular cooling rate to be used depends of course on the nature of the aerosol precursor and other conditions. However, for a particular aerosol precursor it is possible to define a set of testing conditions in order to define the cooling rate, and by extension this imposes limitations on the configuration of the apparatus to permit such cooling rates as are shown to result in advantageous aerosols. Accordingly, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that the cooling rate of the vapour is such that the time taken to cool to 50° C. is not less than 16 ms, when tested according to the following protocol. The aerosol precursor is an e-liquid consisting of 1.6% freebase nicotine and the remainder a 65:35 propylene glycol and vegetable glycerine mixture, the e-liquid having a boiling point of 209° C. Air is drawn into the air inlet at a temperature of 25° C. The vaporiser is operated to release a vapour of total particulate mass 5 mg over a 3 second duration from the vaporiser element surface in an air flow rate between the air inlet and outlet of 1.3 L min⁻¹.

Additionally or alternatively, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that the cooling rate of the vapour is such that the time taken to cool to 50° C. is not less than 16 ms, when tested according to the following protocol. The aerosol precursor is an e-liquid consisting of 1.6% freebase nicotine and the remainder a 65:35 propylene glycol and vegetable glycerine mixture, the e-liquid having a boiling point of 209° C. Air is drawn into the air inlet at a temperature of 25° C. The vaporiser is operated to release a vapour of total particulate mass 5 mg over a 3 second duration from the vaporiser element surface in an air flow rate between the air inlet and outlet of 2.0 L min⁻¹.

Cooling of the vapour such that the time taken to cool to 50° C. is not less than 16 ms corresponds to an equivalent linear cooling rate of not more than 10° C./ms.

The equivalent linear cooling rate of the vapour to 50° C. may be not more than 9° C./ms, not more than 8° C./ms, not more than 7° C./ms, not more than 6° C./ms or not more than 5° C./ms.

Cooling of the vapour such that the time taken to cool to 50° C. is not less than 32 ms corresponds to an equivalent linear cooling rate of not more than 5° C./ms.

The testing protocol set out above considers the cooling of the vapour (and subsequent aerosol) to a temperature of 50° C. This is a temperature which can be considered to be suitable for an aerosol to exit the apparatus for inhalation by a user without causing significant discomfort. It is also possible to consider cooling of the vapour (and subsequent aerosol) to a temperature of 75° C. Although this temperature is possibly too high for comfortable inhalation, it is considered that the particle size characteristics of the aerosol are substantially settled by the time the aerosol cools to this temperature (and they may be settled at still higher temperature).

Accordingly, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that the cooling rate of the vapour is such that the time taken to cool to 75° C. is not less than 4.5 ms, when tested according to the following protocol. The aerosol precursor is an e-liquid consisting of 1.6% freebase nicotine and the remainder a 65:35 propylene glycol and vegetable glycerine mixture, the e-liquid having a boiling point of 209° C. Air is drawn into the air inlet at a temperature of 25° C. The vaporiser is operated to release a vapour of total particulate mass 5 mg over a 3 second duration from the vaporiser element surface in an air flow rate between the air inlet and outlet of 1.3 L min⁻¹.

Additionally or alternatively, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that the cooling rate of the vapour is such that the time taken to cool to 75° C. is not less than 4.5 ms, when tested according to the following protocol. The aerosol precursor is an e-liquid consisting of 1.6% freebase nicotine and the remainder a 65:35 propylene glycol and vegetable glycerine mixture, the e-liquid having a boiling point of 209° C. Air is drawn into the air inlet at a temperature of 25° C. The vaporiser is operated to release a vapour of total particulate mass 5 mg over a 3 second duration from the vaporiser element surface in an air flow rate between the air inlet and outlet of 2.0 L min⁻¹.

Cooling of the vapour such that the time taken to cool to 75° C. is not less than 4.5 ms corresponds to an equivalent linear cooling rate of not more than 30° C./ms.

The equivalent linear cooling rate of the vapour to 75° C. may be not more than 29° C./ms, not more than 28° C./ms, not more than 27° C./ms, not more than 26° C./ms, not more than 25° C./ms, not more than 24° C./ms, not more than 23° C./ms, not more than 22° C./ms, not more than 21° C./ms, not more than 20° C./ms, not more than 19° C./ms, not more than 18° C./ms, not more than 17° C./ms, not more than 16° C./ms, not more than 15° C./ms, not more than 14° C./ms, not more than 13° C./ms, not more than 12° C./ms, not more than 11° C./ms or not more than 10° C./ms.

Cooling of the vapour such that the time taken to cool to 75° C. is not less than 13 ms corresponds to an equivalent linear cooling rate of not more than 10° C./ms.

It is considered that configuring the apparatus in a manner to permit such control of the cooling rate of the vapour permits the generation of aerosols with particularly advantageous particle size characteristics, including Dv50 values.

Development B

[ME ref: 7623218; Nerudia ref: P01205]

For a smoking substitute system it is desirable to deliver nicotine into the user's lungs, where it can be absorbed into the bloodstream. However, the present disclosure is based in part on a realisation that some prior art smoking substitute systems, such delivery of nicotine is not efficient. In some prior art systems, the aerosol droplets have a size distribution that is not suitable for delivering nicotine to the lungs. Aerosol droplets of a large particle size tend to be deposited in the mouth and/or upper respiratory tract. Aerosol particles of a small (e.g. sub-micron) particle size can be inhaled into the lungs but may be exhaled without delivering nicotine to the lungs. As a result the user would require drawing a longer puff, more puffs, or vaporising e-liquid with a higher nicotine concentration in order to achieve the desired experience.

For example, droplets in the 2 to 3 μm range tend to deposit in deep lung, where absorption of nicotine is the most efficient due to the large surface area and the abundant capillary distribution in the deep lung. Therefore, aerosols with droplet size distribution centred in the 2 to 3 μm range will deliver an immediate “nicotine hit”. Droplets in the 3 to 10 μm range tend to deposit in the upper pulmonary area of the lung, where nicotine will be absorbed into blood stream in a slower fashion. As a result, the user will receive a mild but long-lasting nicotine stimulation.

It is of interest to allow the user of a smoking substitute system a degree of control over the aerosol particle size inhaled, in part to take advantage over the phenomena reported above concerning the effect of aerosol particle size on the deposition location within the user's respiratory system.

The present disclosure (Development B) has been devised in the light of the above considerations.

In a general aspect of Development B, the present invention provides suitable user-based control over the aerosol characteristics by the provision of an occlusion member for covering at least one air inlet of a smoking substitute apparatus, the configuration of the occlusion member being determined by a user-selectable engagement of the smoking substitute apparatus with a main body, the smoking substitute apparatus and the main body together constituting a smoking substitute system.

According to a first preferred aspect of Development B there is provided a smoking substitute apparatus comprising:

at least two air inlets;

an aerosol generator for generating an aerosol from an aerosol precursor for inhalation by a user;

an outlet;

at least one air flow path between the air inlet and the outlet for conveying the aerosol to the user;

an occlusion member being selectively configurable between a first configuration in which a first one of said at least two air inlets is covered and a second configuration in which the first one of the at least two air inlets is uncovered;

wherein the first configuration is selectable by the user based on a first engagement arrangement between the smoking substitute apparatus and the main body, and the second configuration is selectable by the user based on a second engagement arrangement between the smoking substitute apparatus and the main body.

According to a second preferred aspect of Development B, there is provided a method of using a smoking substitute apparatus including the step of engaging the smoking substitute apparatus with a main body to provide a smoking substitute system, the smoking substitute apparatus comprising:

-   -   at least two air inlets;     -   an aerosol generator for generating an aerosol from an aerosol         precursor for inhalation by a user;     -   an outlet;     -   at least one air flow path between the air inlet and the outlet         for conveying the aerosol to the user;     -   and     -   an occlusion member;

wherein the method further comprises the steps of selectively configuring the occlusion member between:

-   -   (i) a first configuration in which a first one of the at least         two air inlets is covered, wherein the first configuration is         selected by the user based on a first engagement arrangement         between the smoking substitute apparatus and the main body, and     -   (ii) a second configuration in which the said first one of the         at least two air inlets in uncovered, wherein the second         configuration is selected by the user based on a second         engagement arrangement between the smoking substitute apparatus         and the main body.

According to a third preferred aspect of Development B, there is provided a smoking substitute system comprising a smoking substitute apparatus and a main body, the smoking substitute apparatus being engageable with the main body to provide said smoking substitute system, the smoking substitute apparatus comprising:

-   -   at least two air inlets;     -   an aerosol generator for generating an aerosol from an aerosol         precursor for inhalation by a user;     -   an outlet;     -   at least one air flow path between the air inlet and the outlet         for conveying the aerosol to the user; and     -   an occlusion member;

wherein the occlusion member is selectively configurable between:

-   -   (i) a first configuration in which a first one of the at least         two air inlets is covered, wherein the first configuration is         selected by the user based on a first engagement arrangement         between the smoking substitute apparatus and the main body, and     -   (ii) a second configuration in which the said first one of the         at least two air inlets in uncovered, wherein the second         configuration is selected by the user based on a second         engagement arrangement between the smoking substitute apparatus         and the main body.

The aerosol generator may be provided within a vaporisation chamber, discussed in more detail below. In use, at least a part of the air flow from the air inlet to the outlet may bypasses the vaporisation chamber. This is also discussed in further detail below.

In use, substantially all of the air flow from the air inlet to the outlet may bypass the vaporisation chamber, the vaporisation chamber having a vaporisation chamber outlet in communication with a passage along which air flows from the air inlet to the outlet. This allows particles of aerosol generated by vaporisation of the aerosol precursor to grow to a suitable size prior to becoming entrained in the air flow and inhaled by a user. This provides more efficient nicotine delivery to the user. The vaporisation chamber may be substantially sealed against air flow except for the vaporisation chamber outlet. This further ensures that the particles of the aerosol enter the air flow at substantially the same point in time, ensuring a more homogenous distribution of particle sizes in the air flow.

A first passage may lead from the air inlet to the outlet, the aerosol generator being arranged in fluid communication with the first passage, the apparatus may further comprise an auxiliary passage leading from the air inlet (or from an auxiliary air inlet) to the outlet, wherein the auxiliary passage bypasses the first passage downstream of the aerosol generator. This allows the rate of air flow over the aerosol generator to be maintained at a level low enough to entrain sufficiently sized aerosol particles, even for a user with a high inhalation flow rate.

The first and second configurations of the smoking substitute apparatus permit the user to control aspects of the air flow conditions within the apparatus that affect the aerosol particle size for the reasons discussed in detail above. In the first configuration, in which a first one of said at least two air inlets is covered, the air flow path is between an uncovered air inlet and the outlet. Depending on the positioning of the air inlets relative to the vaporisation chamber and depending on whether there is one or more auxiliary air inlets, the effect of the first configuration can be that there is reduced air flow and/or reduced turbulence at or immediately downstream from the vaporisation chamber. This allows an aerosol to be formed with larger droplet sizes. In the second configuration, in which both of the at least two air inlets are uncovered, the effect of the second configuration can be that there is increased air flow and/or increased turbulence at or immediately downstream from the vaporisation chamber. This allows an aerosol to be formed with smaller droplet sizes. Similarly, the control over the air flow characteristics from the air inlets permits control over the total particulate mass (TPM) of aerosol delivered to the user.

The apparatus is configured to have at least two air inlets. For example, the apparatus may have, for example, two, three, four or five air inlets. In use, at least one of the at least two air inlets typically provides at least one air flow path between the air inlet and the outlet for conveying the aerosol to the user. For example, two air inlets may provide one or two air flow paths, three air inlets may provide one, two or three air flow paths etc. When the occlusion member is in a first configuration, one of the at least two air inlets is covered, for example, in an apparatus comprising two air inlets, one of the air inlets is covered, and in an apparatus comprising three air inlets, one or two of the air inlets is covered. When the occlusion member is in a second configuration, at least one of the air inlets is uncovered. This is to ensure that the apparatus is operable when the occlusion member is in a first configuration and in a second configuration.

A further advantage of the present invention is that the smoking substitute apparatus can be used with an existing main body, because the occlusion member is provided as part of the smoking substitute apparatus.

In a preferred embodiment, the occlusion member is biased towards the second configuration. The second configuration, as a default position, for the reasons explained above may in some embodiments provide a smaller aerosol droplet size (to provide a “nicotine hit” to the user) and an increased TPM. The occlusion member may be biased towards the second configuration by, for example, the occlusion member comprising a resilient material.

Preferably, the occlusion member is a deformable plate. This enables the occlusion member to be changed from its original shape so that it can be configured between the first configuration and the second configuration. The first configuration may therefore be a substantially flat configuration of the plate, covering the air inlet. The second configuration may by a curved configuration of the plate, the curvature of the plate allowing air ingress between at least part of the plate and the air inlet. In this way, the degree of deformation of the occlusion member determines the degree of occlusion of the air inlet and therefore the degree to which air flow at the air inlet is restricted.

Preferably, the occlusion member is arranged such that when the user pushes the smoking substitute apparatus towards the main body, from the second engagement arrangement to the first engagement arrangement, the occlusion member is forced into the first configuration.

The smoking substitute apparatus and the main body may be brought into engagement by insertion of part of the smoking substitute apparatus into a corresponding recess of the main body. The difference between the second and first engagement arrangements may therefore amount to a difference in the insertion distance of the smoking substitute apparatus into the main body.

There may be defined a minimum configuration distance for the smoking substitute apparatus with respect to the main body. This is intended to define the difference in relative distance between the first engagement arrangement and the second engagement arrangement. Starting from the first engagement arrangement, the user may pull the smoking substitute apparatus the minimum configuration distance away from the main body to reach the second engagement arrangement so that the occlusion member reaches (or return to) the second configuration. It is advantageous for the system to provide the user with a haptic indication of reaching the first and/or second engagement arrangement. For example, the user may feel or hear a ‘click’ to alert the user when the minimum configuration distance is reached, indicating that the system is in the second engagement arrangement and therefore that the occlusion member is in the second configuration. The minimum configuration distance may for example be about 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 1 cm.

Development C

[ME Ref: 7628191; Nerudia Ref: P01210]

For a smoking substitute system it is desirable that the user is able to control or customise their experience to some degree, so that they can receive an experience meeting their immediate demands or so that interoperability between various components can be optimised.

The present disclosure presents a simple way in which that control can be achieved, allowing the user easy control of properties such as strength or amount of flavour, strength or amount of nicotine delivered, nicotine particle size and so on.

For a smoking substitute system it is desirable to deliver nicotine into the user's lungs, where it can be absorbed into the bloodstream. However, in some prior art systems, the aerosol droplets have a size distribution that is not suitable for delivering nicotine to the lungs. Aerosol droplets of a large particle size tend to be deposited in the mouth and/or upper respiratory tract. Aerosol particles of a small (e.g. sub-micron) particle size can be inhaled into the lungs but may be exhaled without delivering nicotine to the lungs. As a result the user would require drawing a longer puff, more puffs, or vaporising e-liquid with a higher nicotine concentration in order to achieve the desired experience.

Accordingly, it is of interest to allow the user of a smoking substitute system a degree of control over the aerosol particle size inhaled, in part to take advantage over the phenomena reported above concerning the effect of aerosol particle size on the deposition location within the user's respiratory system.

The present disclosure has been devised in the light of the above considerations.

In a general aspect of Development C, the present invention provides the user with control by rotatable engagement between a main body part and a cartridge part of the smoking substitute system. By rotation, the relative positions of the main body and the cartridge can be altered. In the present invention, the operating conditions of the system are dependent on the relative position of the main body and the cartridge.

According to a first preferred aspect of Development C there is provided a smoking substitute system comprising: a main body comprising a power source for supplying power to a vaporizer; a cartridge comprising a reservoir for containing a liquid aerosol precursor for vaporization by the vaporizer, the cartridge rotatably engagable with the main body so as to be rotatable between a first position in which the system operates according to a first operating condition, and a second position in which the system operates according to a second operating condition that is different to the first operating condition.

According to a second preferred aspect of Development C, there is provided a smoking substitute apparatus comprising a reservoir for containing a liquid aerosol precursor for vaporization by a vaporizer; the smoking substitute apparatus having a retaining means for engaging a main body in a first position or a second position; the smoking substitute apparatus having at least one part selectively configurable between a first configuration and a second configuration, the first and second configurations being different from one another; wherein the first configuration is selectable by the user based on arrangement of the smoking substitute apparatus and the main body in the first position, and the second configuration is selectable by the user based on arrangement of the smoking substitute apparatus and the main body in the second position. The smoking substitute apparatus is rotatably engageable with the main body part, permitting relative rotation of the main body and the cartridge or smoking substitute apparatus to select between the first position and the second position.

It will of course be apparent that the first and second positions, and their corresponding first and second operating conditions, do not limit the present devices to having only two such positions or conditions. For example, it can easily be envisaged that three, four, five or more positions of relative rotation between the main body and the cartridge may be possible, each having a unique operating condition under which the smoking substitute system operates when in that position. Features discussed below with respect to first and second positions or operating conditions apply equally to third, fourth, fifth or higher positions and operating conditions and should be interpreted as such.

Herein, the vaporizer is used as a general term for the components causing vaporization of the liquid aerosol precursor. It may comprise, for example, one or more vaporizer elements, which may absorb the liquid aerosol precursor, and/or one or more heaters, which heat the vaporizer element(s) to generate aerosol.

In the first position the vaporizer may operate under a first condition and in the second position the vaporizer may operate under a second condition which is different from the first condition.

The smoking substitute apparatus may be comprised by or within a cartridge configured for engagement with the main body, the cartridge and main body together forming a smoking substitute system. The smoking substitute apparatus may be removably or releasably engageable with the main body (which may also be referred to herein as the base unit).

The smoking substitute apparatus may be in the form of a consumable. The consumable may be configured for rotatable engagement with a main body. When the consumable is engaged with the main body, the combination of the consumable and the main body may form a smoking substitute system such as a closed smoking substitute system. For example, the consumable may comprise components of the system that are disposable, and the main body may comprise non-disposable or non-consumable components (e.g. power supply, controller, sensor, etc.) that facilitate the generation and/or delivery of aerosol by the consumable. In such an embodiment, the aerosol precursor (e.g. e-liquid) may be replenished by replacing a used consumable with an unused consumable.

Alternatively, the smoking substitute apparatus may be a non-consumable apparatus (e.g. that is in the form of an open smoking substitute system). In such embodiments an aerosol former (e.g. e-liquid) of the system may be replenished by re-filling, e.g. a reservoir of the smoking substitute apparatus, with the aerosol precursor (rather than replacing a consumable component of the apparatus).

In light of this, it should be appreciated that some of the features described herein as being part of the smoking substitute apparatus may alternatively form part of a main body for engagement with the smoking substitute apparatus. This may be the case in particular when the smoking substitute apparatus is in the form of a consumable.

Where the smoking substitute apparatus is in the form of a consumable, the main body and the consumable may be configured to be physically coupled together. For example, the consumable may be at least partially received in a recess of the main body, such that there is an interference fit between the main body and the consumable. Alternatively, the main body and the consumable may be physically coupled together by screwing one onto the other, or through a bayonet fitting, or the like.

Thus, the smoking substitute apparatus may comprise one or more engagement portions for engaging with a main body. In this way, one end of the smoking substitute apparatus may be coupled with the main body, whilst an opposing end of the smoking substitute apparatus may define a mouthpiece of the smoking substitute system.

The engagement portions may hold the main body and cartridge in at least one of their possible rotational configurations. In some embodiments, engagement portions are provided which hold the main body and the cartridge in both the first position and the second position defined above. That is, either the main body or the cartridge comprises one or more retaining means which engages the other of the cartridge or the main body to hold the cartridge in the first position or the second position. In some embodiments, either the main body or the cartridge comprises a first retaining means which engages the other of the cartridge or the main body to hold the cartridge in the first position; and either the main body or the cartridge comprises a second retaining means which engages the other of the cartridge or the main body to hold the cartridge in the second position. In some embodiments both the cartridge and the main body are provided with some form of retaining means or engagement portion. Those may cooperate (for example, a protrusion on the main body may cooperate with a cavity on the cartridge and vice versa; or a magnet on the main body may cooperate with a magnetic material area on the cartridge and vice versa).

This means that the smoking substitute system may be provided with a ‘default’ position (for example, that in which the retaining means holds the main body and the cartridge); there may be a different ‘active’ position in which the rotation is not held, thus encouraging the user to return to the default position. This is suitable where the ‘active’ position corresponds to an operating condition which is favourable only for short periods. Indeed, the smoking substitute system may comprise biasing means to bias the relative rotation of the main body and the cartridge toward the ‘default’ position.

Alternatively, where means are provided to hold the relative rotation of the main body and the cartridge in each of the first and second positions, this is suitable where the positions each correspond to favourable operating condition for long term use.

There may be a release mechanism which disengages the engagement portions temporarily to allow relative rotation of the main body and the cartridge, for example to move to a different position.

The or each retaining means or engagement portion may comprise a magnet. A magnet on one of the main body and the cartridge may be positioned to engage with one or more areas of magnetic material on the other of the main body and cartridge. The magnetic attraction between the magnet and the closest area of magnetic material can hold the main body and cartridge in a first position (first area of magnetic material) and a second position (second area of magnetic material). By providing multiple such areas, the relative rotation of the main body and the cartridge can move the magnet from one area to another, indexing the rotation between various positions. In the present invention each such position can be associated with a different operating condition of the smoking substitute system.

If there are multiple magnets on one of the main body and the cartridge they may be positioned annularly around the surface with will engage with the other of the main body and the cartridge.

In some embodiments, the main body comprises a first series of magnets or magnetic material areas and the cartridge comprises a second series of magnets or magnetic materials (at least one of the main body and cartridge having at least one magnet), whereby rotation of the cartridge with respect to the main body causes different ones of the first series the second series of magnets to engage. This defines a further indexing between the main body and the cartridge, allowing easy selection of different operating conditions.

The same features can be envisaged for retaining means or engagement portions which are of other designs, such as a series of cooperating projections and cavities (convex and concave portions). Rotation of the main body and cartridge with respect to one another means that a first cooperation between a pair is broken, and further rotation creates a new cooperation in a different rotational configuration. Accordingly a mechanical indexing is possible.

There may be embodiments where there is no ‘indexing’ between first and second positions, giving a broadly free level of rotation between the main body and the cartridge while they are held together by the engagement portion or retaining means. This can be useful to provide a sliding scale which is varied by the user according to rotation.

The smoking substitute apparatus may comprise a reservoir configured to store an aerosol precursor, such as an e-liquid. The e-liquid may, for example, comprise a base liquid. The e-liquid may further comprise nicotine. The base liquid may include propylene glycol and/or vegetable glycerine. The e-liquid may be substantially flavourless. That is, the e-liquid may not contain any deliberately added additional flavourant and may consist solely of a base liquid of propylene glycol and/or vegetable glycerine and nicotine.

The reservoir may be in the form of a tank. At least a portion of the tank may be light-transmissive. For example, the tank may comprise a window to allow a user to visually assess the quantity of e-liquid in the tank. A housing of the smoking substitute apparatus may comprise a corresponding aperture (or slot) or window that may be aligned with a light-transmissive portion (e.g. window) of the tank. The reservoir may be referred to as a “clearomizer” if it includes a window, or a “cartomizer” if it does not.

The smoking substitute apparatus may comprise multiple such reservoirs. In the first and second operating conditions, the reservoir from which aerosol precursor is vaporized may be different; or the proportion of aerosol precursor vaporized from the reservoirs may be different. For example, a first positon might correspond to vaporization from a first reservoir, and a second position to vaporization from a second reservoir. A first positon might correspond to vaporization from a first reservoir alone, and a second position to vaporization from a first and second reservoir together. The second position might merely add vapour from the second reservoir to that from the first reservoir already provided in the first position; or the second position may be accompanied with a reduction in vapour from the first reservoir. The first and second reservoirs may contain different flavoured or unflavoured precursors; precursors of different strengths (nicotine contents); and so on.

For example, the cartridge may comprise a first reservoir for containing a first liquid aerosol precursor for vaporization by the vaporizer and a second reservoir for containing a second liquid aerosol precursor for vaporization by the vaporizer; and in the first operating condition the first liquid aerosol precursor may be is vaporized by the vaporizer and in the second operating condition the second liquid aerosol precursor may be vaporized by the vaporizer.

In some embodiments the first operating condition and the second operating condition may differ by the amount, identity or content of the liquid aerosol precursor vaporized by the vaporizer. This allows the user to customise these properties of their experience, giving access to new flavour combinations, vapour strengths and mouth feels and so on.

In embodiments where there is no ‘indexing’ between first and second positions, giving a broadly free level of rotation between the main body and the cartridge, the sliding scale may be useful for the user to fade between different flavours, or strengths and so on, to give maximal customisation of experience.

The outlet may be at a mouthpiece of the smoking substitute apparatus. In this respect, a user may draw fluid (e.g. air) into and through the passage by inhaling at the outlet (i.e. using the mouthpiece). The passage may be at least partially defined by the tank. The tank may substantially (or fully) define the passage, for at least a part of the length of the passage. In this respect, the tank may surround the passage, e.g. in an annular arrangement around the passage.

The vaporisation chamber may be arranged to be in fluid communication with the inlet and outlet of the passage. The vaporisation chamber may be an enlarged portion of the passage. In this respect, the air as drawn in by the user may entrain the generated vapour in a flow away from a heater. The entrained vapour may form an aerosol in the vaporisation chamber, or it may form the aerosol further downstream along the passage. The vaporisation chamber may be at least partially defined by the tank. The tank may substantially (or fully) define the vaporisation chamber, and thus may form the enclosure. In this respect, the tank may surround the vaporisation chamber, e.g. in an annular arrangement around the vaporisation chamber.

In use, the user may puff on a mouthpiece of the smoking substitute apparatus, i.e. draw on the smoking substitute apparatus by inhaling, to draw in an air stream therethrough. The part of the air flow which bypasses the vaporisation chamber (dilution air flow) may combine with the other part of the air flow (main air flow) for diluting the aerosol contained therein. The dilution air flow may be directly inhaled by the user without passing through the passage of the smoking substitute apparatus.

As a user puffs on the mouthpiece, vaporised e-liquid entrained in the passing air flow may be drawn towards the outlet of the passage. The vapour may cool, and thereby nucleate and/or condense along the passage to form a plurality of aerosol droplets, e.g. nicotine-containing aerosol droplets. A portion of these aerosol droplets may be delivered to and be absorbed at a target delivery site, e.g. a user's lung, whilst a portion of the aerosol droplets may instead adhere onto other parts of the user's respiratory tract, e.g. the user's oral cavity and/or throat. Typically, in some known smoking substitute apparatuses, the aerosol droplets as measured at the outlet of the passage, e.g. at the mouthpiece, may have a droplet size, d₅₀, of less than 1 μm.

In some embodiments of the invention, the d₅₀ particle size of the aerosol particles is preferably at least 1 μm, more preferably at least 2 μm. Typically, the d₅₀ particle size is not more than 10 μm, preferably not more than 9 μm, not more than 8 μm, not more than 7 μm, not more than 6 μm, not more than 5 μm, not more than 4 μm or not more than 3 μm. It is considered that providing aerosol particle sizes in such ranges permits improved interaction between the aerosol particles and the user's lungs.

The particle droplet size, d₅₀, of an aerosol may be measured by a laser diffraction technique. For example, the stream of aerosol output from the outlet of the passage may be drawn through a Malvern Spraytec laser diffraction system, where the intensity and pattern of scattered laser light are analysed to calculate the size and size distribution of aerosol droplets. As will be readily understood, the particle size distribution may be expressed in terms of d₁₀, d₅₀ and d₉₀, for example. Considering a cumulative plot of the volume of the particles measured by the laser diffraction technique, the d₁₀ particle size is the particle size below which 10% by volume of the sample lies. The d₅₀ particle size is the particle size below which 50% by volume of the sample lies. The d₅₀ particle size is the particle size below which 90% by volume of the sample lies. Unless otherwise indicated herein, the particle size measurements are volume-based particle size measurements, rather than number-based or mass-based particle size measurements.

The spread of particle size may be expressed in terms of the span, which is defined as (d₉₀−d₁₀)/d₅₀. Typically, the span is not more than 20, preferably not more than 10, preferably not more than 8, preferably not more than 4, preferably not more than 2, preferably not more than 1, or not more than 0.5.

The particle size of the aerosol may be affected by the choice of the first or second (or further) position or operating condition by the user. For example, the first position and second position may be associated with different air flows through the device. For example, the first position may correspond to a configuration in which part of the air flow bypasses the vaporisation chamber, and the second position may correspond to a configuration in which a smaller or larger amount of the air flow bypasses the vaporisation chamber.

Alternatively or additionally, the first and second positions may make other changes to the air flow. For example, they may cause a structural change to the air flow path, for example lengthening it, introducing constrictions or broadenings into its cross section, altering the size or shape of the inlet or outlet and so on.

For example, where the smoking substitute system comprises an air inlet, an outlet, and at least one air flow path between the air inlet and the outlet for conveying vaporized liquid aerosol precursor to the user, the first operating condition and the second operating condition may have different air flow between the air inlet and the outlet. The first operating condition and the second operating condition may differ by the size of the air inlet. The first operating condition and the second operating condition may differ by the length, shape or cross-section of the air flow path.

That is, multiple different inlets, outlets, or air flow paths between them may be provided in the present smoking substitute systems. Selection between the first position and second position can alter which inlet, which outlet, and/or which air flow path is active at a given time.

For example, in a smoking substitute apparatus, the smoking substitute apparatus may comprise an air inlet and an outlet, and have a first air flow path between the air inlet and the outlet which is operable in the first configuration and a second air flow path between the air inlet and the outlet which is operable in the second configuration; or the smoking substitute apparatus may comprise multiple air inlets and an outlet, and have a first air flow path between a first air inlet and the outlet which is operable in the first configuration and a second air flow path between a second air inlet and the outlet which is operable in the second configuration.

For example, the first operating condition may correspond to an arrangement in which the main air flow is through a first air flow path between the air inlet and the outlet; and the second operating condition may correspond to an arrangement in which the main air flow is through a second air flow path between the air inlet and the outlet, the first and second air flow paths being different.

For example, the main body may comprise a first body air inlet and a second body air inlet, and the cartridge may comprise a cartridge air inlet and the outlet; and the smoking substitute system may comprise an air flow path through the cartridge air inlet and one of the body air inlets to the outlet; and in the first position the air flow path is through the first body air inlet and in the second position the air flow path is through the second body air inlet.

For example, the main body may comprise a body air inlet, and the cartridge may comprise a first cartridge air inlet, a second cartridge air inlet and the outlet; and the smoking substitute system may comprise an air flow path through one of the cartridge air inlets and the body air inlet to the outlet; and in the first position the air flow path is through the first cartridge air inlet and in the second position the air flow path is through the second cartridge air inlet.

The smoking substitute apparatus (or main body engaged with the smoking substitute apparatus) may comprise a power source. The power source may be electrically connected (or connectable) to a heater of the smoking substitute apparatus (e.g. when the smoking substitute apparatus is engaged with the main body). The power source may be a battery (e.g. a rechargeable battery). A connector in the form of e.g. a USB port may be provided for recharging this battery.

The power supplied by the power source may differ in the first and second operating conditions. For example, one may have a lower power than the other. This has knock on effects on the amount and properties of vapour produced. That is, the first operating condition and the second operating condition may differ by the amount of power supplied to the vaporizer.

Additionally or alternatively the first and second operation conditions may route power to different parts of the smoking substitute system, for example to ‘activate’ or ‘deactivate’ reservoir(s).

Similarly, the first operating condition may correspond to an ‘active’ arrangement in which the vaporization of the liquid aerosol precursor by the vaporizer is possible; and the second operating condition may correspond to an ‘inactive’ arrangement in which the vaporization of the liquid aerosol precursor by the vaporizer is impossible. This enable a safety lock so the user can prevent accidental activation of the device.

When the smoking substitute apparatus is in the form of a consumable, the smoking substitute apparatus may comprise an electrical interface for interfacing with a corresponding electrical interface of the main body. One or both of the electrical interfaces may include one or more electrical contacts. Thus, when the main body is engaged with the consumable, the electrical interface of the main body may be configured to transfer electrical power from the power source to a heater of the consumable via the electrical interface of the consumable.

Relative rotation of the main body and the cartridge may cause the electrical interface of the main body to engage with a different electrical interface of the consumable, or vice versa. That is, the main body and/or the consumable or cartridge may have multiple electrical interfaces, the first and second operating conditions corresponding to engagement between different pairs of these electrical interfaces.

The electrical interface of the smoking substitute apparatus may also be used to identify the smoking substitute apparatus (in the form of a consumable) from a list of known types. For example, the consumable may have a certain concentration of nicotine and the electrical interface may be used to identify this. The electrical interface may additionally or alternatively be used to identify when a consumable is connected to the main body.

This means that rotation of the main body and the cartridge as described herein can, for example, switch between preferred operating conditions for different types of consumable.

Again, where the smoking substitute apparatus is in the form of a consumable, the main body may comprise an identification means, which may, for example, be in the form of an RFID reader, a barcode or QR code reader. This identification means may be able to identify a characteristic (e.g. a type) of a consumable engaged with the main body. In this respect, the consumable may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the identification means.

The smoking substitute apparatus or main body may comprise a controller, which may include a microprocessor. The controller may be configured to control the supply of power from the power source to the heater of the smoking substitute apparatus (e.g. via the electrical contacts). A memory may be provided and may be operatively connected to the controller. The memory may include non-volatile memory. The memory may include instructions which, when implemented, cause the controller to perform certain tasks or steps of a method.

The main body or smoking substitute apparatus may comprise a wireless interface, which may be configured to communicate wirelessly with another device, for example a mobile device, e.g. via Bluetooth®. To this end, the wireless interface could include a Bluetooth® antenna. Other wireless communication interfaces, e.g. WiFi®, are also possible. The wireless interface may also be configured to communicate wirelessly with a remote server.

A puff sensor may be provided that is configured to detect a puff (i.e. inhalation from a user). The puff sensor may be operatively connected to the controller so as to be able to provide a signal to the controller that is indicative of a puff state (i.e. puffing or not puffing). The puff sensor may, for example, be in the form of a pressure sensor or an acoustic sensor. That is, the controller may control power supply to the heater of the consumable in response to a puff detection by the sensor. The control may be in the form of activation of the heater in response to a detected puff. That is, the smoking substitute apparatus may be configured to be activated when a puff is detected by the puff sensor. When the smoking substitute apparatus is in the form of a consumable, the puff sensor may be provided in the consumable or alternatively may be provided in the main body.

The term “flavourant” is used to describe a compound or combination of compounds that provide flavour and/or aroma. For example, the flavourant may be configured to interact with a sensory receptor of a user (such as an olfactory or taste receptor). The flavourant may include one or more volatile substances.

The flavourant may be provided in solid or liquid form. The flavourant may be natural or synthetic. For example, the flavourant may include menthol, liquorice, chocolate, fruit flavour (including e.g. citrus, cherry etc.), vanilla, spice (e.g. ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed or may be provided in isolated locations and/or varying concentrations.

The present inventors consider that a flow rate of 1.3 L min⁻¹ is towards the lower end of a typical user expectation of flow rate through a conventional cigarette and therefore through a user-acceptable smoking substitute apparatus. The present inventors further consider that a flow rate of 2.0 L min⁻¹ is towards the higher end of a typical user expectation of flow rate through a conventional cigarette and therefore through a user-acceptable smoking substitute apparatus. Embodiments of the present invention therefore provide an aerosol with advantageous particle size characteristics across a range of flow rates of air through the apparatus. By altering the operating condition of the smoking substitute system, the properties of the aerosol may be correspondingly altered to the user's preference.

For example:

In the first or second position, the aerosol may have a Dv50 of at least 1.1 μm, at least 1.2 μm, at least 1.3 μm, at least 1.4 μm, at least 1.5 μm, at least 1.6 μm, at least 1.7 μm, at least 1.8 μm, at least 1.9 μm or at least 2.0 μm.

The aerosol may have a Dv50 of not more than 4.9 μm, not more than 4.8 μm, not more than 4.7 μm, not more than 4.6 μm, not more than 4.5 μm, not more than 4.4 μm, not more than 4.3 μm, not more than 4.2 μm, not more than 4.1 μm, not more than 4.0 μm, not more than 3.9 μm, not more than 3.8 μm, not more than 3.7 μm, not more than 3.6 μm, not more than 3.5 μm, not more than 3.4 μm, not more than 3.3 μm, not more than 3.2 μm, not more than 3.1 μm or not more than 3.0 μm.

A particularly preferred range for Dv50 of the aerosol is in the range 2-3 μm.

In the first or second position, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber is in the range 0-1.3 ms⁻¹. The average magnitude velocity of air may be calculated based on knowledge of the geometry of the vaporisation chamber and the flow rate.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber may be at most 1.2 ms⁻¹, at most 1.1 ms⁻¹, at most 1.0 ms⁻¹, at most 0.9 ms⁻¹, at most 0.8 ms⁻¹, at most 0.7 ms⁻¹ or at most 0.6 ms⁻¹.

In the first or second position, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber is in the range 0-1.3 ms⁻¹. The average magnitude velocity of air may be calculated based on knowledge of the geometry of the vaporisation chamber and the flow rate.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporisation chamber may be at most 1.2 ms⁻¹, at most 1.1 ms⁻¹, at most 1.0 ms⁻¹, at most 0.9 ms⁻¹, at most 0.8 ms⁻¹, at most 0.7 ms⁻¹ or at most 0.6 ms⁻¹.

When the calculated average magnitude of velocity of air in the vaporisation chamber is in the ranges specified, it is considered that the resultant aerosol particle size is advantageously controlled to be in a desirable range. It is further considered that the configuration of the apparatus can be selected so that the average magnitude of velocity of air in the vaporisation chamber can be brought within the ranges specified, at the exemplary flow rate of 1.3 L min⁻¹ and/or the exemplary flow rate of 2.0 L min⁻¹.

The vaporizer or aerosol generator may comprise a vaporiser element loaded with aerosol precursor, the vaporiser element being heatable by a heater and presenting a vaporiser element surface to air in the vaporisation chamber. A vaporiser element region may be defined as a volume extending outwardly from the vaporiser element surface to a distance of 1 mm from the vaporiser element surface.

The operation of the aerosol generator or vaporizer may differ between the first and second operating conditions. For example, the power supplied, circuits activated, or aerosol precursor loaded or vaporized may differ between the first and second operating conditions.

In the first or second position, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region is in the range 0-1.2 ms⁻¹. The average magnitude of velocity of air in the vaporiser element region may be calculated using computational fluid dynamics. The average magnitude of velocity of air in the vaporiser element region may differ between the first and second operating conditions.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region may be at most 1.1 ms⁻¹, at most 1.0 ms⁻¹, at most 0.9 ms⁻¹, at most 0.8 ms⁻¹, at most 0.7 ms⁻¹ or at most 0.6 ms⁻¹.

In the first or second position, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region is in the range 0-1.2 ms⁻¹. The average magnitude of velocity of air in the vaporiser element region may be calculated using computational fluid dynamics.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the average magnitude of velocity of air in the vaporiser element region may be at most 1.1 ms⁻¹, at most 1.0 ms⁻¹, at most 0.9 ms⁻¹, at most 0.8 ms⁻¹, at most 0.7 ms⁻¹ or at most 0.6 ms⁻¹.

When the average magnitude of velocity of air in the vaporiser element region is in the ranges specified, it is considered that the resultant aerosol particle size is advantageously controlled to be in a desirable range. It is further considered that the velocity of air in the vaporiser element region is more relevant to the resultant particle size characteristics than consideration of the velocity in the vaporisation chamber as a whole. This is in view of the significant effect of the velocity of air in the vaporiser element region on the cooling of the vapour emitted from the vaporiser element surface.

Additionally or alternatively is it relevant to consider the maximum magnitude of velocity of air in the vaporiser element region.

Therefore, in the first or second position, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region is in the range 0-2.0 ms⁻¹. The maximum magnitude of velocity of air in the vaporiser element region may differ between the first and second operating conditions.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region may be at most 1.9 ms⁻¹, at most 1.8 ms⁻¹, at most 1.7 ms⁻¹, at most 1.6 ms⁻¹, at most 1.5 ms⁻¹, at most 1.4 ms⁻¹, at most 1.3 ms⁻¹ or at most 1.2 ms⁻¹.

In the first or second position, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region is in the range 0-2.0 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region may be at least 0.001 ms⁻¹, or at least 0.005 ms⁻¹, or at least 0.01 ms⁻¹, or at least 0.05 ms⁻¹.

When the air flow rate inhaled by the user through the apparatus is 2.0 L min⁻¹, the maximum magnitude of velocity of air in the vaporiser element region may be at most 1.9 ms⁻¹, at most 1.8 ms⁻¹, at most 1.7 ms⁻¹, at most 1.6 ms⁻¹, at most 1.5 ms⁻¹, at most 1.4 ms⁻¹, at most 1.3 ms⁻¹ or at most 1.2 ms⁻¹.

It is considered that configuring the apparatus in a manner to permit such control of velocity of the airflow at the vaporiser permits the generation of aerosols with particularly advantageous particle size characteristics, including Dv50 values.

Additionally or alternatively is it relevant to consider the turbulence intensity in the vaporiser chamber in view of the effect of turbulence on the particle size of the generated aerosol. For example, in the first or second position, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that, when the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the turbulence intensity in the vaporiser element region is not more than 1%. The turbulence intensity in the vaporiser element region may differ between the first and second operating conditions.

When the air flow rate inhaled by the user through the apparatus is 1.3 L min⁻¹, the turbulence intensity in the vaporiser element region may be not more than 0.95%, not more than 0.9%, not more than 0.85%, not more than 0.8%, not more than 0.75%, not more than 0.7%, not more than 0.65% or not more than 0.6%.

It is considered that configuring the apparatus in a manner to permit such control of the turbulence intensity in the vaporiser element region permits the generation of aerosols with particularly advantageous particle size characteristics, including Dv50 values.

Following detailed investigations, the inventors consider, without wishing to be bound by theory, that the particle size characteristics of the generated aerosol may be determined by the cooling rate experienced by the vapour after emission from the vaporiser element (e.g. wick). In particular, it appears that imposing a relatively slow cooling rate on the vapour has the effect of generating aerosols with a relatively large particle size. The parameters discussed above (velocity and turbulence intensity) are considered to be mechanisms for implementing a particular cooling dynamic to the vapour.

More generally, it is considered that the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that a desired cooling rate is imposed on the vapour. The particular cooling rate to be used depends of course on the nature of the aerosol precursor and other conditions. However, for a particular aerosol precursor it is possible to define a set of testing conditions in order to define the cooling rate, and by extension this imposes limitations on the configuration of the apparatus to permit such cooling rates as are shown to result in advantageous aerosols. Accordingly, in the first or second position, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that the cooling rate of the vapour is such that the time taken to cool to 50° C. is not less than 16 ms, when tested according to the following protocol. The aerosol precursor is an e-liquid consisting of 1.6% freebase nicotine and the remainder a 65:35 propylene glycol and vegetable glycerine mixture, the e-liquid having a boiling point of 209° C. Air is drawn into the air inlet at a temperature of 25° C. The vaporiser is operated to release a vapour of total particulate mass 5 mg over a 3 second duration from the vaporiser element surface in an air flow rate between the air inlet and outlet of 1.3 L min⁻¹.

Additionally or alternatively, in the first or second position, the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that the cooling rate of the vapour is such that the time taken to cool to 50° C. is not less than 16 ms, when tested according to the following protocol. The aerosol precursor is an e-liquid consisting of 1.6% freebase nicotine and the remainder a 65:35 propylene glycol and vegetable glycerine mixture, the e-liquid having a boiling point of 209° C. Air is drawn into the air inlet at a temperature of 25° C. The vaporiser is operated to release a vapour of total particulate mass 5 mg over a 3 second duration from the vaporiser element surface in an air flow rate between the air inlet and outlet of 2.0 L min⁻¹.

The cooling rate of the vapour, in particular the time taken to cool to 50° C., may differ between the first and second operating conditions.

Cooling of the vapour such that the time taken to cool to 50° C. is not less than 16 ms corresponds to an equivalent linear cooling rate of not more than 10° C./ms.

The equivalent linear cooling rate of the vapour to 50° C. may be not more than 9° C./ms, not more than 8° C./ms, not more than 7° C./ms, not more than 6° C./ms or not more than 5° C./ms.

Cooling of the vapour such that the time taken to cool to 50° C. is not less than 32 ms corresponds to an equivalent linear cooling rate of not more than 5° C./ms.

The testing protocol set out above considers the cooling of the vapour (and subsequent aerosol) to a temperature of 50° C. This is a temperature which can be considered to be suitable for an aerosol to exit the apparatus for inhalation by a user without causing significant discomfort. It is also possible to consider cooling of the vapour (and subsequent aerosol) to a temperature of 75° C. Although this temperature is possibly too high for comfortable inhalation, it is considered that the particle size characteristics of the aerosol are substantially settled by the time the aerosol cools to this temperature (and they may be settled at still higher temperature).

Accordingly, in the first or second position the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that the cooling rate of the vapour is such that the time taken to cool to 75° C. is not less than 4.5 ms, when tested according to the following protocol. The aerosol precursor is an e-liquid consisting of 1.6% freebase nicotine and the remainder a 65:35 propylene glycol and vegetable glycerine mixture, the e-liquid having a boiling point of 209° C. Air is drawn into the air inlet at a temperature of 25° C. The vaporiser is operated to release a vapour of total particulate mass 5 mg over a 3 second duration from the vaporiser element surface in an air flow rate between the air inlet and outlet of 1.3 L min⁻¹.

Additionally or alternatively, in the first or second position the air inlet, flow passage, outlet and the vaporisation chamber may be configured so that the cooling rate of the vapour is such that the time taken to cool to 75° C. is not less than 4.5 ms, when tested according to the following protocol. The aerosol precursor is an e-liquid consisting of 1.6% freebase nicotine and the remainder a 65:35 propylene glycol and vegetable glycerine mixture, the e-liquid having a boiling point of 209° C. Air is drawn into the air inlet at a temperature of 25° C. The vaporiser is operated to release a vapour of total particulate mass 5 mg over a 3 second duration from the vaporiser element surface in an air flow rate between the air inlet and outlet of 2.0 L min⁻¹.

The cooling rate of the vapour, in particular the time taken to cool to 75° C., may differ between the first and second operating conditions.

Cooling of the vapour such that the time taken to cool to 75° C. is not less than 4.5 ms corresponds to an equivalent linear cooling rate of not more than 30° C./ms.

The equivalent linear cooling rate of the vapour to 75° C. may be not more than 29° C./ms, not more than 28° C./ms, not more than 27° C./ms, not more than 26° C./ms, not more than 25° C./ms, not more than 24° C./ms, not more than 23° C./ms, not more than 22° C./ms, not more than 21° C./ms, not more than 20° C./ms, not more than 19° C./ms, not more than 18° C./ms, not more than 17° C./ms, not more than 16° C./ms, not more than 15° C./ms, not more than 14° C./ms, not more than 13° C./ms, not more than 12° C./ms, not more than 11° C./ms or not more than 10° C./ms.

Cooling of the vapour such that the time taken to cool to 75° C. is not less than 13 ms corresponds to an equivalent linear cooling rate of not more than 10° C./ms.

It is considered that configuring the apparatus in a manner to permit such control of the cooling rate of the vapour permits the generation of aerosols with particularly advantageous particle size characteristics, including Dv50 values.

The invention includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

SUMMARY OF THE FIGURES

So that the invention may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the invention will now be discussed in further detail with reference to the accompanying figures, in which:

FIG. 1 illustrates a set of rectangular tubes for use in experiments to assess the effect of flow and cooling conditions at the wick on aerosol properties. Each tube has the same depth and length but different width.

FIG. 2 shows a schematic perspective longitudinal cross sectional view of an example rectangular tube with a wick and heater coil installed.

FIG. 3 shows a schematic transverse cross sectional view an example rectangular tube with a wick and heater coil installed. In this example, the internal width of the tube is 12 mm.

FIGS. 4A-4D show air flow streamlines in the four devices used in a turbulence study.

FIG. 5 shows the experimental set up to investigate the influence of inflow air temperature on aerosol particle size, in order to investigate the effect of vapour cooling rate on aerosol generation.

FIG. 6 shows a schematic longitudinal cross sectional view of a first smoking substitute apparatus (pod 1) used to assess influence of inflow air temperature on aerosol particle size.

FIG. 7 shows a schematic longitudinal cross sectional view of a second smoking substitute apparatus (pod 2) used to assess influence of inflow air temperature on aerosol particle size.

FIG. 8A shows a schematic longitudinal cross sectional view of a third smoking substitute apparatus (pod 3) used to assess influence of inflow air temperature on aerosol particle size. FIG. 8B shows a schematic longitudinal cross sectional view of the same third smoking substitute apparatus (pod 3) in a direction orthogonal to the view taken in FIG. 8A.

FIG. 9 shows a plot of aerosol particle size (Dv50) experimental results against calculated air velocity.

FIG. 10 shows a plot of aerosol particle size (Dv50) experimental results against the flow rate through the apparatus for a calculated air velocity of 1 m/s.

FIG. 11 shows a plot of aerosol particle size (Dv50) experimental results against the average magnitude of the velocity in the vaporiser surface region, as obtained from CFD modelling.

FIG. 12 shows a plot of aerosol particle size (Dv50) experimental results against the maximum magnitude of the velocity in the vaporiser surface region, as obtained from CFD modelling.

FIG. 13 shows a plot of aerosol particle size (Dv50) experimental results against the turbulence intensity.

FIG. 14 shows a plot of aerosol particle size (Dv50) experimental results dependent on the temperature of the air and the heating state of the apparatus.

FIG. 15 shows a plot of aerosol particle size (Dv50) experimental results against vapour cooling rate to 50° C.

FIG. 16 shows a plot of aerosol particle size (Dv50) experimental results against vapour cooling rate to 75° C.

FIG. 17 is a schematic front view of a smoking substitute system, according to a first embodiment, in an engaged position;

FIG. 18 is a schematic front view of the smoking substitute system of the first embodiment in a disengaged position;

FIG. 19 is a schematic longitudinal cross sectional view of a smoking substitute apparatus of a first reference arrangement;

FIG. 20 is an enlarged schematic cross sectional view of part of the air passage and vaporisation chamber of the first reference arrangement;

FIG. 21 shows a schematic cross sectional view of a smoking substitute apparatus of a second reference arrangement;

FIG. 22 shows a schematic cross sectional view of a smoking substitute apparatus of a third reference arrangement;

Figure A23 shows a schematic partial cross sectional view of a smoking substitute apparatus of an embodiment of Development A, the cross sectional view taken perpendicular to the axis of the wick;

Figure A24 shows a schematic partial cross sectional view of the apparatus of FIG. 23 , the cross sectional view taken parallel to the axis of the wick;

Figure A25 shows a partial cross sectional view of an electrical conductor partially moulded into the inner wall of the upstream portion of the air flow path of an embodiment of Development A;

Figure A26 shows a partial cross sectional view of an electrical conductor fully moulded into the inner wall of the upstream portion of the air flow path of another embodiment of Development A.

Figure B23 shows a schematic partial cross sectional view of a smoking substitute apparatus according to an embodiment of the invention of Development B when the occlusion member is in a first configuration.

Figure B24 shows the embodiment of FIG. 23 but with the occlusion member removed, corresponding to a second configuration.

Figure B25 shows a schematic partial perspective view of the base of the smoking substitute apparatus of Figure B23 when the occlusion member is in the first configuration.

Figure B26 shows a schematic partial perspective view of the base of the smoking substitute apparatus of Figure B23 when the occlusion member is in the second configuration.

Figure B27 is a perspective side view of a smoking substitute system according to an embodiment of the invention of Development B when the smoking substitute apparatus is in a first engagement arrangement with the main body.

Figure B28 is a perspective side view of a smoking substitute system according to an embodiment of the invention of Development B when the smoking substitute apparatus is in a second engagement arrangement with the main body.

Figure B29 shows an enlarged schematic perspective cross sectional view taken parallel to the principal axis of the wick and parallel to the principal axis of the apparatus, showing interior features of the smoking substitute apparatus and the main body when the occlusion member is in the second configuration.

Figure B30 shows an enlarged schematic perspective cross sectional view taken parallel to the principal axis of the wick and parallel to the principal axis of the apparatus, showing interior features of the smoking substitute apparatus and the main body when the occlusion member is in the first configuration.

Figure C23 shows a schematic side view of a main body of a smoking substitute system of a first embodiment of Development C.

Figure C24 shows a schematic top view of the main body of Figure C23 of Development C.

Figure C25 shows a schematic isometric view a cartridge of a smoking substitute apparatus of a first embodiment of Development C.

Figure C26 shows a schematic isometric cross-sectional view of the interface between the main body of Figures C23 and C24, and the cartridge of Figure C25.

Figure C27 shows a series of views of the interface between a main body and a cartridge in a smoking substitute apparatus of a second embodiment of Development C, wherein (a) shows a position where an inlet on the outer face of the cartridge aligns with an inlet on the core surface of the main body. (b), (c) and (d) illustrate other alternative inlets on the core surface of the main body. (e) and (f) illustrate positions of the main body and cartridge in which the inlet on the outer face of the cartridge aligns with different ones of the inlets illustrated in (b), (c) and (d).

DETAILED DESCRIPTION OF THE INVENTION

Further background to the present invention and further aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. The contents of all documents mentioned in this text are incorporated herein by reference in their entirety.

FIGS. 17 and 18 illustrate a smoking substitute system in the form of an e-cigarette system 110. The system 110 comprises a main body 120 of the system 110, and a smoking substitute apparatus in the form of an e-cigarette consumable (or “pod”) 150. In the illustrated embodiment the consumable 150 (sometimes referred to herein as a smoking substitute apparatus) is removable from the main body 120, so as to be a replaceable component of the system 110. The e-cigarette system 110 is a closed system in the sense that it is not intended that the consumable should be refillable with e-liquid by a user.

As is apparent from FIGS. 17 and 18 , the consumable 150 is configured to engage the main body 120. FIG. 17 shows the main body 120 and the consumable 150 in an engaged state, whilst FIG. 18 shows the main body 120 and the consumable 150 in a disengaged state. When engaged, a portion of the consumable 150 is received in a cavity of corresponding shape in the main body 120 and is retained in the engaged position by way of a snap-engagement mechanism. In other embodiments, the main body 120 and consumable 150 may be engaged by screwing one into (or onto) the other, or through a bayonet fitting, or by way of an interference fit.

The system 110 is configured to vaporise an aerosol precursor, which in the illustrated embodiment is in the form of a nicotine-based e-liquid 160. The e-liquid 160 comprises nicotine and a base liquid including propylene glycol and/or vegetable glycerine. In the present embodiment, the e-liquid 160 is flavoured by a flavourant. In other embodiments, the e-liquid 160 may be flavourless and thus may not include any added flavourant.

FIG. 19 shows a schematic longitudinal cross sectional view of a reference arrangement of the smoking substitute apparatus forming part of the smoking substitute system shown in FIGS. 17 and 18 . In FIG. 19 , the e-liquid 160 is stored within a reservoir in the form of a tank 152 that forms part of the consumable 150. In the illustrated reference arrangement, the consumable 150 is a “single-use” consumable 150. That is, upon exhausting the e-liquid 160 in the tank 152, the intention is that the user disposes of the entire consumable 150. The term “single-use” does not necessarily mean the consumable is designed to be disposed of after a single smoking session. Rather, it defines the consumable 150 is not arranged to be refilled after the e-liquid contained in the tank 152 is depleted. The tank may include a vent (not shown) to allow ingress of air to replace e-liquid that has been used from the tank. The consumable 150 preferably includes a window 158 (see FIGS. 17 and 18 ), so that the amount of e-liquid in the tank 152 can be visually assessed. The main body 120 includes a slot 157 so that the window 158 of the consumable 150 can be seen whilst the rest of the tank 152 is obscured from view when the consumable 150 is received in the cavity of the main body 120. The consumable 150 may be referred to as a “clearomizer” when it includes a window 158, or a “cartomizer” when it does not.

In some embodiments, the e-liquid (i.e. aerosol precursor) may be the only part of the system that is truly “single-use”. That is, the tank may be refillable with e-liquid or the e-liquid may be stored in a non-consumable component of the system. For example, in such embodiments, the e-liquid may be stored in a tank located in the main body or stored in another component that is itself not single-use (e.g. a refillable cartomizer).

The external wall of tank 152 is provided by a casing of the consumable 150. The tank 152 annularly surrounds, and thus defines a portion of, a passage 170 that extends between a vaporiser inlet 172 and an outlet 174 at opposing ends of the consumable 150. In this respect, the passage 170 comprises an upstream end at the end of the consumable 150 that engages with the main body 120, and a downstream end at an opposing end of the consumable 150 that comprises a mouthpiece 154 of the system 110.

When the consumable 150 is received in the cavity of the main body 120 as shown in FIG. 19 , a plurality of device air inlets 176 are formed at the boundary between the casing of the consumable and the casing of the main body. The device air inlets 176 are in fluid communication with the vaporiser inlet 172 through an inlet flow channel 178 formed in the cavity of the main body which is of corresponding shape to receive a part of the consumable 150. Air from outside of the system 110 can therefore be drawn into the passage 170 through the device air inlets 176 and the inlet flow channels 178.

When the consumable 150 is engaged with the main body 120, a user can inhale (i.e. take a puff) via the mouthpiece 154 so as to draw air through the passage 170, and so as to form an airflow (indicated by the dashed arrows in FIG. 19 ) in a direction from the vaporiser inlet 172 to the outlet 174. Although not illustrated, the passage 170 may be partially defined by a tube (e.g. a metal tube) extending through the consumable 150. In FIG. 19 , for simplicity, the passage 170 is shown with a substantially circular cross-sectional profile with a constant diameter along its length. In some embodiments, the passage may have other cross-sectional profiles, such as oval shaped or polygonal shaped profiles. Further, in other embodiments, the cross sectional profile and the diameter (or hydraulic diameter) of the passage may vary along its longitudinal axis.

The smoking substitute system 110 is configured to vaporise the e-liquid 160 for inhalation by a user. To provide this operability, the consumable 150 comprises a heater having a porous wick 162 and a resistive heating element in the form of a heating filament 164 that is helically wound (in the form of a coil) around a portion of the porous wick 162. The porous wick 162 extends across the passage 170 (i.e. transverse to a longitudinal axis of the passage 170 and thus also transverse to the air flow along the passage 170 during use) and opposing ends of the wick 162 extend into the tank 152 (so as to be immersed in the e-liquid 160). In this way, e-liquid 160 contained in the tank 152 is conveyed from the opposing ends of the porous wick 162 to a central portion of the porous wick 162 so as to be exposed to the airflow in the passage 170.

The helical filament 164 is wound about the exposed central portion of the porous wick 162 and is electrically connected to an electrical interface in the form of electrical contacts 156 mounted at the end of the consumable that is proximate the main body 120 (when the consumable and the main body are engaged). When the consumable 150 is engaged with the main body 120, electrical contacts 156 make contact with corresponding electrical contacts (not shown) of the main body 120. The main body electrical contacts are electrically connectable to a power source (not shown) of the main body 120, such that (in the engaged position) the filament 164 is electrically connectable to the power source. In this way, power can be supplied by the main body 120 to the filament 164 in order to heat the filament 164. This heats the porous wick 162 which causes e-liquid 160 conveyed by the porous wick 162 to vaporise and thus to be released from the porous wick 162. The vaporised e-liquid becomes entrained in the airflow and, as it cools in the airflow (between the heated wick and the outlet 174 of the passage 170), condenses to form an aerosol. This aerosol is then inhaled, via the mouthpiece 154, by a user of the system 110. As e-liquid is lost from the heated portion of the wick, further e-liquid is drawn along the wick from the tank to replace the e-liquid lost from the heated portion of the wick.

The filament 164 and the exposed central portion of the porous wick 162 are positioned across the passage 170. More specifically, the part of passage that contains the filament 164 and the exposed portion of the porous wick 162 forms a vaporisation chamber. In the illustrated example, the vaporisation chamber has the same cross-sectional diameter as the passage 170. However, in some embodiments the vaporisation chamber may have a different cross sectional profile compared with the passage 170. For example, the vaporisation chamber may have a larger cross sectional diameter than at least some of the downstream part of the passage 170 so as to enable a longer residence time for the air inside the vaporisation chamber.

FIG. 20 illustrates in more detail the vaporisation chamber and therefore the region of the consumable 150 around the wick 162 and filament 164. The helical filament 164 is wound around a central portion of the porous wick 162. The porous wick extends across passage 170. E-liquid 160 contained within the tank 152 is conveyed as illustrated schematically by arrows 401, i.e. from the tank and towards the central portion of the porous wick 162.

When the user inhales, air is drawn from through the inlets 176 shown in FIG. 19 , along inlet flow channel 178 to vaporisation chamber inlet 172 and into the vaporisation chamber containing porous wick 162. The porous wick 162 extends substantially transverse to the airflow direction. The airflow passes around the porous wick, at least a portion of the airflow substantially following the surface of the porous wick 162. In examples where the porous wick has a cylindrical cross-sectional profile, the airflow may follow a curved path around an outer periphery of the porous wick 162.

At substantially the same time as the airflow passes around the porous wick 162, the filament 164 is heated so as to vaporise the e-liquid which has been wicked into the porous wick. The airflow passing around the porous wick 162 picks up this vaporised e-liquid, and the vapour-containing airflow is drawn in direction 403 further down passage 170.

The power source of the main body 120 may be in the form of a battery (e.g. a rechargeable battery such as a lithium ion battery). The main body 120 may comprise a connector in the form of e.g. a USB port for recharging this battery. The main body 120 may also comprise a controller that controls the supply of power from the power source to the main body electrical contacts (and thus to the filament 164). That is, the controller may be configured to control a voltage applied across the main body electrical contacts, and thus the voltage applied across the filament 164. In this way, the filament 164 may only be heated under certain conditions (e.g. during a puff and/or only when the system is in an active state). In this respect, the main body 120 may include a puff sensor (not shown) that is configured to detect a puff (i.e. inhalation). The puff sensor may be operatively connected to the controller so as to be able to provide a signal, to the controller, which is indicative of a puff state (i.e. puffing or not puffing). The puff sensor may, for example, be in the form of a pressure sensor or an acoustic sensor.

Although not shown, the main body 120 and consumable 150 may comprise a further interface which may, for example, be in the form of an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g. a type) of a consumable 150 engaged with the main body 120. In this respect, the consumable 150 may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

An apparatus according to an embodiment of the invention may be configured such that in use, at least part of the air flow drawn by a user through the apparatus from the air inlet to the outlet bypasses the vaporisation chamber defined by the enclosure. A second reference arrangement of an apparatus, shown in FIG. 21 , provides an example of how such a bypassing air flow may be created. Accordingly, some embodiments of the invention may include one or a combination of the features of the second reference arrangement (and variations thereof) where such features are combinable with the present invention. This second reference arrangement is described below.

FIG. 21 illustrates a schematic longitudinal cross sectional view of a second reference arrangement of the smoking substitute apparatus forming part of the smoking substitute system shown in FIGS. 17 and 18 . The arrangement illustrated in FIG. 21 differs from the first reference arrangement illustrated in FIG. 19 in that the substitute smoking apparatus includes two bypass passages 180 in addition to the vaporiser passage 170. The bypass air passages extend between the plurality of device air inlets 176 and two outlets 184. In other variations of the second reference arrangement, the number of bypass passages 180 and corresponding outlets 184 may be greater or smaller than in the illustrated example. Furthermore, there may be more or fewer air inlets and there may be more or fewer outlets.

In FIG. 21 for simplicity, the bypass passage 180 is shown with a substantially circular cross-sectional profile with a constant diameter along its length. In some variations of the second reference arrangement, the bypass passage 180 may have other cross-sectional profiles, such as oval shaped or polygonal shaped profiles. Further, in some variations of the second reference arrangement, the cross sectional profile and the diameter (or hydraulic diameter) of the bypass passage 180 may vary along its longitudinal axis.

The provision of a bypass passage 180 means that a part of the air drawn through the smoking substitute apparatus 150 a when a user inhales via the mouthpiece 154 is not drawn through the vaporisation chamber. This has the effect of reducing the flow rate through the vaporisation chamber in correspondence with the respective flow resistances presented by the vaporiser passage 170 and the bypass passage 180. This can reduce the correlation between the flow rate through the smoking substitute apparatus 150 a (i.e. the user's draw rate) and the particle size generated when the e-liquid 160 is vaporised and subsequently forms an aerosol. Therefore, the smoking substitute apparatus 150 a of the second reference arrangement can deliver a more consistent aerosol to a user.

Furthermore, the smoking substitute apparatus 150 a of the second reference arrangement is capable of producing an increased particle droplet size, d₅₀, based on typical inhalation rates undertaken by a user, compared to the first reference arrangement of FIG. 19 . Such larger droplet sizes may be beneficial for the delivery of vapour to a user's lungs. The preferred ratio between the dimensions of the bypass passage 180 and the dimensions of the vaporiser passage 170, and hence flow rate in the respective passages may be determined from representative user inhalation rates and from the required air flow rate through the vaporisation chamber to deliver a desired droplet size. For example, an average total flow rate of 1.3 litres per minute may be split such that 0.8 litres per minute passes through the bypass air channel 180, and 0.5 litres per minute passes through the vaporiser channel 170, a bypass:vaporiser flow rate ratio of 1.6:1. Such a flow rate may provide an average droplet size, d₅₀, of 1-3 μm (more preferably 2-3 μm) with a span of not more than 20 (preferably not more than 10). Alternative flow rate ratios may be provided based on calculations and measurements of user flow rate, vaporiser flow rate, and average droplet size d₅₀. A bypass:vaporiser flow rate ratio of between 0.5:1 and 20:1, typically at an average total flow rate of 1.3 litres per minute may be advantageous depending on the configuration of the smoking substitute apparatus.

The bypass passage and vaporiser passage extend from a common device inlet 176. This has the benefit of ensuring more consistent airflow through the bypass passage 180 and vaporiser passage 170 across the lifetime of the smoking substitute apparatus 150 a, since any obstruction that impinges on an air inlet 176 will affect the airflow through both passages equally. The impact of inlet manufacturing variations can also be reduced for the same reason. This can therefore improve the user experience for the smoking substitute apparatus 150 a. Furthermore, the provision of a common device inlet 176 simplifies the construction and external appearance of the device.

The bypass passage 180 and vaporiser passage 170 separate upstream of the vaporisation chamber. Therefore, no vapour is drawn through the bypass passage 180. Furthermore, because the bypass passage leads to outlet 184 that is separate from outlet 174 of the vaporiser passage, substantially no mixing of the bypass air and vaporiser air occurs within the smoking substitute apparatus 150 a. Such mixing could otherwise lead to excessive cooling of the vapour and hence a build-up of condensation within the smoking substitute apparatus 150 a. Such condensation could have adverse implications for delivering vapour to the user, for example by causing the user to draw liquid droplets rather than vapour when “puffing” on the mouthpiece 154.

A further example of a bypass air flow is presented by a third reference arrangement. Accordingly, in some embodiments, the apparatus may include one or a combination of features of a third reference arrangement (and variations thereof), shown schematically in FIG. 22 , where such features are combinable with the present invention. This third reference arrangement is described below.

FIG. 22 illustrates a longitudinal cross sectional view of a consumable 250 according to a further arrangement. In FIG. 22 , the consumable 250 is shown attached, at a first end of the consumable 250, to the main body 120 of FIG. 17 and FIG. 18 . More specifically, the consumable 250 is configured to engage and disengage with the main body 120 and is interchangeable with the first reference arrangement 150 as shown in FIGS. 19 and 20 . Furthermore, the consumable 250 is configured to interact with the main body 120 in the same manner as the first reference arrangement 150 and the user may operate the consumable 250 in the same manner as the first reference arrangement 150.

The consumable 250 comprises a housing. The consumable 250 comprises an aerosol generation chamber 280 in the housing. As shown in FIG. 22 , the aerosol generation chamber 280 takes the form of an open ended container, or a cup, with a single chamber outlet 282 opened towards the outlet 274 of the consumable 250.

In the illustrated third reference arrangement, the housing has a plurality of air inlets 272 defined or opened at the sidewall of the housing. An outlet 274 is defined or opened at a second end of the consumable 250 that comprises a mouthpiece 254. A pair of passages 270 each extend between the respective air inlets 272 and the outlet 274 to provide flow passage for an air flow 412 as a user puffs on the mouthpiece 254. The chamber outlet 282 is configured to be in fluid communication with the passages 270. The passages 270 extend from the air inlets 272 towards the first end of the consumable 250 before routing back to towards the outlet 274 at the second end of the consumable 250. That is, a portion of each of the passages 270 axially extends alongside the aerosol generation chamber 280. The path of the air flow path 412 is illustrated in FIG. 22 . In variations of the third reference arrangement, the passages 270 may extend from the air inlet 272 directly to the outlet 274 without routing towards the first end of consumable 250, e.g. the passages 270 may not axially extend alongside the aerosol generation chamber 280.

In some other variations of the third reference arrangement, the housing may not be provided with any air inlet for an air flow to enter the housing. For example, the chamber outlet may be directly connected to the outlet of the housing by an aerosol passage and therefore said aerosol passage may only convey aerosol as generated in the aerosol generation chamber. In these variations, the discharge of aerosol may be driven at least in part by the pressure increase during vaporisation of aerosol form.

Referring back to the third reference arrangement of FIG. 22 , the chamber outlet 282 is positioned downstream from the heater in the direction of the vapour and/or aerosol flow 414 and serves as the only gas flow passage to the internal volume of the aerosol generation chamber 280. In other words, the aerosol generation chamber 280 is sealed against air flow except for having the chamber outlet 282 in communication with the passages 270, the chamber outlet 282 permitting, in use, aerosol generated by the heater to be entrained into an air flow along the passage 270. In some other variations of the third reference arrangement, the sealed aerosol generation chamber 280 may comprise a plurality of chamber outlets 282 each arranged in fluid commutation with the passages 270. In the illustrated third reference arrangement, the aerosol generation chamber 280 does not comprise any aperture upstream of the heater that may serve as an air flow inlet (although in some arrangements a vent may be provided). In contrast with the consumable 150 as shown in FIGS. 19 and 20 , the passages 270 of the consumable 250 allow the air flow, e.g. an entire amount of air flow, entering the housing to bypass the aerosol generation chamber 280. Such arrangement allows aerosol precursor to be vaporised in absence of the air flow. Therefore, the aerosol generation chamber may be considered to be a “stagnant” chamber. For example, the volumetric flowrate of vapour and/or aerosol in the aerosol generation chamber is configured to be less than 0.1 litre per minute. The vaporised aerosol precursor may cool and therefore condense to form an aerosol in the aerosol generation chamber 280, which is subsequently expulsed into or entrained with the air flow in passages 270. In addition, a portion of the vaporised aerosol precursor may remain as a vapour before leaving the aerosol generation chamber 280, and subsequently forms an aerosol as it is cooled by the air flow in the passages 270. The flow path of the vapour and/or aerosol 414 is illustrated in FIG. 22 .

In the illustrated third reference arrangement, the chamber outlet 282 is configured to be in fluid communication with a junction 290 at each of the passages 270 through a respective vapour channel 292. The junctions 290 merge the vapour channels 292 with their respective passages 270 such that vapour and/or aerosol formed in the aerosol generation chamber 280 may expand or entrain into the passages 270 through junction inlets of said junctions 290. The vapour channels form a buffering volume to minimise the amount of air flow that may back flow into the aerosol generation chamber 280. In some other variations of the third reference arrangement (not illustrated), the chamber outlet 282 may directly open towards the junction 290 at the passage, and therefore in such variations the vapour channel 292 may be omitted.

In some variations of the third reference arrangement (not illustrated), the chamber outlet may be closed by a one way valve. Said one way valve may be configured to allow a one way flow passage for the vapour and/or aerosol to be discharged from the aerosol generation chamber, and to reduce or prevent the air flow in the passages from entering the aerosol generation chamber.

In the illustrated third reference arrangement, the aerosol generation chamber 280 is configured to have a length of 20 mm and a volume of 680 mm³. The aerosol generation chamber is configured to allow vapour to be expulsed through the chamber outlet ata rate greater than 0.1 mg/second. In other variations of the third reference arrangement the aerosol generation chamber may be configured to have an internal volume ranging between 68 mm³ to 680 mm³, wherein the length of the aerosol generation chamber may range between 2 mm to 20 mm.

As shown in FIG. 22 , a part of each of the passages 270 axially extends alongside the aerosol generation chamber 280. For example, the passages 270 are formed between the aerosol generation chamber 280 and the housing. Such an arrangement reduces heat transfer from the aerosol generation chamber 280 to the external surfaces of the housing.

The aerosol generation chamber 280 comprises a heater extending across its width. The heater comprises a porous wick 262 and a heating filament 264 helically wound around a portion of the porous wick 162. A tank 252 is provided in the space between the aerosol generation chamber 280 and the outlet 274, the tank being for storing a reservoir of aerosol precursor. Therefore in contrast with the reference arrangement as shown in FIGS. 19 and 20 , the tank 252 in the third reference arrangement does not substantially surround the aerosol generation chamber nor the passage 270. Instead, as shown in FIG. 22 , the tank is substantially positioned above the aerosol generation chamber 280 and the porous wick 262 when the consumable 250 is placed in an upright orientation during use. The end portions of the porous wick 262 each extend through the sidewalls of the aerosol generation chamber 280 and into a respective liquid conduit 266 which is in fluid communication with the tank 252. The wick 262, saturated with aerosol precursor, may prevent gas flow passage into the liquid conduits 266 and the tank 252. Such an arrangement may allow the aerosol precursor stored in the tank 252 to convey towards the porous wick 262 through the liquid conduits 266 by gravity. The liquid conduits 266 are configured to have a hydraulic diameter that allow a controlled amount of aerosol precursor to flow from the tank 252 towards the porous wick 262. More specifically, the size of liquid conduits 266 are selected based on the rate of aerosol precursor consumption during vaporisation. For example, the liquid conduits 266 are sized to allow a sufficient amount of aerosol precursor to flow towards and replenish the wick, yet not so large as to cause excessive aerosol precursor to leak into the aerosol generation chamber. The liquid conduits 266 are configured to have a hydraulic diameter ranging from 0.01 mm to 10 mm or 0.01 mm to 5 mm. Preferably, the liquid conduits 266 are configured to have a hydraulic diameter in the range of 0.1 mm to 1 mm.

The heating filament is electrically connected to electrical contacts 256 at the base of the aerosol generation chamber 280, sealed to prevent air ingress or fluid leakage. As shown in FIG. 22 , when the first end of the consumable 250 is received into the main body 120, the electrical contacts 256 establish electrical communication with corresponding electrical contacts of the main body 120, and thereby allow the heater to be energised.

The vaporised aerosol precursor, or aerosol in the condensed form, may discharge from the aerosol generation chamber 280 based on pressure difference between the aerosol generation chamber 280 and the passages 270. Such pressure difference may arise form i) an increased pressure in the aerosol generation chamber 280 during vaporisation of aerosol form, and/or ii) a reduced pressure in the passage during a puff.

For example, when the heater is energised and forms a vapour, it expands in to the stagnant cavity of the aerosol generation chamber 280 and thereby causes an increase in internal pressure therein. The vaporised aerosol precursor may immediately begin to cool and may form aerosol droplets. Such increase in internal pressure causes convection inside the aerosol generation chamber which aids expulsing aerosol through the chamber outlet 282 and into the passages 270.

In the illustrated third reference arrangement, the heater is positioned within the stagnant cavity of the aerosol generation chamber 280, e.g. the heater is spaced from the chamber outlet 282. Such arrangement may reduce or prevent the amount of air flow entering the aerosol generation chamber, and therefore it may minimise the amount of turbulence in the vicinity of the heater. Furthermore, such arrangement may increase the residence time of vapour in the stagnant aerosol generation chamber 280, and thereby may result in the formation of larger aerosol droplets. In some other variations of the third reference arrangement, the heater may be positioned adjacent to the chamber outlet and therefore that the path of vapour 414 from the heater to the chamber outlet 282 is shortened. This may allow vapour to be drawn into or entrained with the air flow in a more efficient manner.

The junction inlet at each of the junctions 290 opens in a direction orthogonal or non-parallel to the air flow. That is, the junction inlet each opens at a sidewall of the respective passages 270. This allows the vapour and/or aerosol from the aerosol generation chamber 280 to entrain into the air flow at an angle, and thus improving localised mixing of the different streams, as well as encouraging aerosol formation. The aerosol may be fully formed in the air flow and be drawn out through the outlet at the mouthpiece.

With the absence of, or much reduced, air flow in the aerosol generation chamber, the aerosol as generated by the illustrated third reference arrangement has a median droplet size d₅₀ of at least 1 μm. More preferably, the aerosol as generated by the illustrated third reference arrangement has a median droplet size d₅₀ of ranged between 2 μm to 3 μm.

Development A

[ME Ref: 7624570; Nerudia Ref: P01221]

Figure A23 shows a schematic partial cross sectional view of a smoking substitute apparatus of an embodiment, the cross sectional view taken perpendicular to the axis of the wick. Figure A24 shows a schematic partial cross sectional view of the apparatus of Figure A23 , the cross sectional view taken parallel to the axis of the wick. This embodiment can be considered to be a modification of the embodiment of FIGS. 17 and 18 . The general construction of the apparatus is similar to the arrangement shown in FIG. 19 , with the exception of the construction of the upstream portion of the air flow path and the electrical contacts leading to the heating element.

Figures A23 and A24 show the part of the apparatus close to the aerosol generator, which is formed from wick a162 a and heater element a164 a coiled around the wick a162 a.

The apparatus has an air flow path extending generally axially along an air flow passage, between an air inlet (not shown) to an outlet (not shown). The air flow path has an upstream region and a downstream region as illustrated, these regions being upstream and downstream of the aerosol generator, respectively. The upstream portion a120 a of the air flow path is defined at least in part by an inner wall a140 a of the apparatus, the inner wall being formed from plastics material by moulding. Electrical connectors a142 a and a144 a are provided, for electrically connecting the heating element a164 a to a power source (not shown). The electrical connectors a142 a and a144 a extend along the inner wall a140 a of the upstream portion of the air flow path in a direction generally parallel to the air flow direction. The electrical connectors a142 a and a144 a are at least partially moulded into the inner wall a140 a.

Figure A25 shows a partial cross sectional view of an electrical conductor partially moulded into the inner wall a140 a of the upstream portion of the air flow path of an embodiment. Figure A26 shows a partial cross sectional view of an electrical conductor fully moulded into the inner wall a140 a of the upstream portion of the air flow path of another embodiment.

Considering a length direction of the electrical connector a142 a, a 144 a, the length direction may be substantially parallel to the air flow direction along the air flow path in the upstream portion a120 a. Along the length of the electrical connector, some parts of the length may be moulded, or partially moulded, into the inner wall of the upstream portion of the air flow path. Other parts of the electrical connector, for example one of more parts between the parts of the length that are moulded into the inner wall, may simply abut the inner wall by virtue of the moulded parts.

Each electrical connector has a strip shape a142 a, a 144 a, with the length of the strip corresponding to the length direction mentioned above, a width direction corresponding to a circumferential direction of the upstream portion of the air flow path, perpendicular to the length direction, and a depth direction corresponding to a radial direction of the upstream portion of the air flow path, perpendicular to both the length direction and the circumferential direction. The width of the electrical connector is w and the depth is d.

As shown in Figure A24, the width of the electrical connector may vary along its length. In particular, in Figure A24, the electrical connector has wide portions a145 a at which the electrical connectors is moulded or partially moulded to the inner wall a140 a of the upstream portion. Narrow portions a146 a are disposed between said wide portions a145 a. The narrow portions a146 a abut the inner wall without being moulded into the inner wall. In this embodiment, the wide portions a145 a have a generally circular region. The inner wall may be moulded into an aperture a147 a formed in the wide portions.

Figures A25 and A26 illustrate two different configurations for an electrical connector with respect to the inner wall a140 a. In Figure A26, the electrical connector a144 c is moulded into the inner wall a140 a such that the entire depth d of the electrical connector is embedded in the inner wall a140 a. The effect of this is that the main surface a152 c is coplanar with the surface of the inner wall a140 a facing the air flow.

In Figure A25, the electrical connector a144 b is moulded into the inner wall a140 a such that only part of the depth d of the electrical connector is embedded in the inner wall a140 a. Here, about half of the depth of the electrical connector is embedded into the inner wall a140 a. The effect of this is that the main surface a152 b is not coplanar with the surface of the inner wall a140 a facing the air flow.

Dashed line a190 a in the upstream portion of the air flow path in Figures A23 and A24 is intended in indicate the boundary between the air and the inner wall a140 a or the electrical contacts a142 a, a 144 a. Similarly, dashed line a191 a in the downstream portion of the air flow path in these drawings is intended to indicate the boundary for the air flowing downstream of the aerosol generator.

By using the features of the present invention, it becomes possible to increase the available diameter D1, D2 of the upstream portion of the air flow path. It will be understood that other design and engineering considerations apply to the construction of the apparatus and the upstream portion of the air flow path and so, within those constraints, implementing the embodiments of the present invention aims to maximise the available cross sectional area (determined in part by D1 and D2) for the air flow. For a particular air flow rate (e.g. corresponding to a typical inhalation rate), therefore, the flow conditions in the upstream portion of the air flow path can have relatively low velocity and preferably relatively low (or no) turbulence. By ensuring that the electrical connectors present in the upstream portion of the air flow path are at least partially moulded into the inner wall, there is provided a greater cross sectional area for the air to flow through the apparatus to the aerosol generator than would otherwise be the case. Having a greater cross sectional area upstream of the aerosol generator results in a reduced average air flow velocity for the same air flow rate. As explained (and shown) in more detail above, it is considered that this can result in slower cooling of the vapour emitted by the aerosol generator and can in turn result in a larger average particle size, and preferably a more uniform particle size distribution, for the generated aerosol.

The downstream portion of the air flow path also has a relatively large cross sectional area, indicated by diameters D3 and D4. This cross sectional area is similar to and typically slightly larger than the cross sectional area of the upstream portion of the air flow path.

Development B

[ME Ref: 7623218; Nerudia Ref: P01205]

Figure B23 shows a schematic cross sectional view through the aerosol generation chamber (also disclosed herein as the vaporisation chamber) of the smoking substitute apparatus b110C. The smoking substitute apparatus b110C comprises a first air inlet b120C, a second air inlet b122C and an outlet (not shown). The outlet is at an opposing side to the first and second air inlets. The smoking substitute apparatus also comprises an occlusion member b140C. The occlusion member b140C is arranged to either cover the second air inlet b122C, as shown in Figure B23, which illustrates a first configuration of the occlusion member, or leave the second air inlet uncovered, as shown in Figure B24, which illustrates a second configuration of the occlusion member (the occlusion member being omitted from this view). The smoking substitute apparatus further comprises a first air inlet passage b124C extending from the first air inlet b120C, and a second air inlet passage b126C extending from the second air inlet b122C. The first air inlet passage b124C and the second air inlet passage b126C extend to at least partially bypass aerosol generator chamber b130C which comprises an aerosol generator b132C. The aerosol generator comprises a wick b162C and a heater b164C in the form of a metal coil wrapped around the wick.

As will be understood from the preceding discussion, the embodiment shown in Figure B23 is a type of stagnant chamber device, in which the air inlet does not directly jet air onto the aerosol generator. This is found to be advantageous in the context of the generation of relatively large aerosol particles.

In use, when the occlusion member is in a first configuration, as shown in Figure B23, air enters the second air inlet b120C and flows along an air flow path A only, from the second air inlet b120C, through the second air inlet passage b124C and just downstream of the aerosol generator chamber b130C. The air is guided along a first part of the aerosol generator chamber by a guide b150C, which also serves as an electrical contact to the heater, so that the incoming air is not directed at the aerosol generator. As the air passes the end of the guide b150C, vapour and/or aerosol particles, generated by the aerosol generator, are entrained in the air, to form an aerosol. The aerosol moves towards the outlet, to be inhaled by the user.

In use, when the occlusion member is in a second configuration, as shown in Figure B24, air enters both the first air inlet b120C and the second air inlet b122C and flows along air flow paths A and B. The air flows through the first air inlet passage b124C and the second air inlet passage b126C. Downstream of the first air inlet passage b124C and the second air inlet passage b126C, the air is separated from the aerosol generator by guides b150C, b152C so that the air does not come into direct contact with the aerosol generator b132C. Once the air flow paths A and B pass the guides b150C, the air flow is directed to move substantially axially through the apparatus towards the outlet (not shown). Aerosol particles are entrained in the air flow. The guide b152C for the air flow path B is shown as being shorter than guide b150C for air flow path A. However, this is in view of the guides' additional function as electrical contacts for heater b164. Each is sufficiently long to reduce the risk of air flow being directed at the aerosol generator.

Figure B25 shows a schematic partial perspective view of the base of the smoking substitute apparatus of Figure B23 when the occlusion member b140C is in the first configuration (also known as a ‘closed position’), in which the second air inlet is covered.

Figure B26 shows a schematic partial perspective view of the base of the smoking substitute apparatus of Figure B23 when the occlusion member b140C is in the second configuration (also known as an ‘open position’), in which the second air inlet b122C is uncovered.

In the first configuration, shown in Figure B25, the occlusion member b140C lies flat across a base b270C of the smoking substitute apparatus to cover the second air inlet (hidden from view and therefore not shown). In the second configuration, shown in Figure B26, the occlusion member b140C is curved in shape and provides access for air to enter the second air inlet b122C. The occlusion member b140C in Figures B25 and B26 is in the shape of a plate.

Figure B27 is a perspective side view of a smoking substitute system according to an embodiment of the invention when the smoking substitute apparatus b110C is in a first engagement arrangement with the main body b310C. The smoking substitute system presents two air inlets (only one shown at b320C) and a mouthpiece b360C for a user to inhale the aerosol. The smoking substitute apparatus b110C comprises bar b330C configured to slide into a corresponding slot formed in the main body b310C, permitting easy location and a positive engagement between the smoking substitute apparatus and the main body.

A first engagement arrangement is selected by the user when the exterior casings of smoking substitute apparatus b110C and the main body b310C are fully engaged, as shown in Figure B27. In the first configuration, the occlusion member is in a first configuration, shown in Figures B23 and B25. In this engagement position, the second air inlet b122C is covered and so air is not permitted to travel along air flow path B.

A second engagement arrangement is selected by the user when the exterior casings of the smoking substitute apparatus b110C and the main body b310C are partially separated, as shown in Figure B28. In this engagement arrangement, the occlusion member is in a second configuration, shown in Figures B24 and 26, and the second air inlet b122C is uncovered and so air is permitted to travel along air flow path A and air flow path B. In order to get the smoking substitute apparatus and main body into the second engagement arrangement from the first engagement arrangement, a user pulls the exterior casing of the smoking substitute apparatus b110C away from the main body b310C. When the smoking apparatus b110C and the main body b310C are partially separated, a gap b350C forms between the casing of the smoking apparatus and the casing of the main body, and the occlusion member, which comprises a resilient material, is released, such that it uncovers the second air inlet, as shown in Figures B24 and B26.

Figure B29 shows an enlarged schematic perspective cross sectional view taken parallel to the principal axis of the wick and parallel to the principal axis of the apparatus, showing interior features of the smoking substitute apparatus and the main body when the occlusion member is in the second configuration. The dashed line in Figure B29 denotes a separation line between the substitute smoking apparatus and the main body. When the substitute smoking apparatus and main body are engaged, the occlusion member b140C can be moved from a first configuration to a second configuration, and vice versa, by the action of a user pushing or pulling the smoking substitute apparatus towards or away from the main body. Pins b420C connect the battery (not shown) in the main body, with the aerosol generator in the smoking substitute apparatus, to provide power to the aerosol generator.

In Figure B30, the occlusion member b140C is in the first configuration, and is lying flat against the base b270C of the smoking substitute apparatus. The occlusion member is forced into the first configuration by a fixed protrusion b430C in the interior casing of the main body. When the user pushes the smoking substitute apparatus towards the main body, the occlusion member becomes compressed against the protrusion b430C in the main body, which causes the occlusion member to flatten and cover the second air inlet.

In Figure B29, the occlusion member b140C is curved in shape, and allows air to enter the second air inlet. When the user pulls the exterior casing of smoking substitute apparatus b110C away from the exterior casing of the main body at least a minimum configuration distance, the protrusion b430C in the interior casing of the main body no longer compresses the occlusion member b140C. Because the occlusion member b140C is made of a resilient material, it returns to its original shape, which is a curved shape, after being compressed. The occlusion member is now in the second configuration.

Development C

[ME Ref: 7628191; Nerudia Ref: P01210]

In embodiments of the present invention, the main body and cartridge (smoking substitute apparatus, or ‘consumable’ herein) may be rotatably engagable. The mechanism for this is not visible in FIGS. 17 and 18 .

As is apparent from FIGS. 17 and 18 , and as explained above, the consumable 150 is configured to engage the main body 120. FIG. 17 shows the main body 120 and the consumable 150 in an engaged state, whilst FIG. 18 shows the main body 120 and the consumable 150 in a disengaged state. When engaged, a portion of the consumable 150 is received in a cavity of corresponding shape in the main body 120 and is retained in the engaged position by way of a snap-engagement mechanism. In other embodiments, the main body 120 and consumable 150 may be engaged by screwing one into (or onto) the other, or through a bayonet fitting, or by way of an interference fit. Additionally or alternatively, one or both of them may be fitted with one or more magnet and/or areas of magnetic material, for example on the surface(s) intended to come into contact with the other part, to magnetically engage the main body 120 and the consumable 150.

An apparatus according to an embodiment of the invention may be configured such that in use, at least part of the air flow drawn by a user through the apparatus from the air inlet to the outlet bypasses the vaporisation chamber defined by the enclosure. In particular, it may be configured so that when the main body 120 and the consumable 150 are in a certain rotational relationship, a first position, at least part of the air flow drawn by a user through the apparatus from the air inlet to the outlet bypasses the vaporisation chamber defined by the enclosure; and in a different rotational relationship, a second position, none of the air flow drawn by a user through the apparatus from the air inlet to the outlet bypasses the vaporisation chamber defined by the enclosure.

In embodiments of the present invention, the first and second positions, or further positions, may correspond to positions in which a selection of the air inlets are open or closed, to modify air flow through the passages.

As explained above, there may be multiple possible electrical contacts provided on the consumable and/or the main body. By rotating the main body and consumable with respect to one another, from a first position to a second position for example, different electrical contacts may be made. This can enable the user to alter, for example, the power supplied to the heater. In embodiments where multiple reservoirs are present, it may enable the user to switch between or otherwise alter the balance between vapour from each reservoir. For example, in the consumable there may be a first circuit attached to a heater for a first reservoir and a second circuit attached to a heater for a second reservoir. In the first position the electrical contacts in the main body connect to the first circuit, enabling aerosol precursor liquid in the first reservoir to be vaporized. In the second position the electrical contacts in the main body connect to the second circuit, enabling aerosol precursor liquid in the second reservoir to be vaporized.

To further illustrate the possibilities of the invention, Figures C23-C27 are provided to show embodiments of the interface between the main body and the consumable or cartridge. This illustrate how the rotation of the two with respect to one another may operate to provide multiple positions each associated with a particular operating condition of the smoking substitute system.

Figure C23 shows a main body c120 having a trunk portion c220 and an outer interface portion c230. The trunk portion c220 is illustrated as having a tubular shape, with an approximately circular cross section, but it will of course be appreciated that these shapes can be freely varied. The outer interface portion c230 is a tubular projection from a contact surface c221, the contact surface c221 forming a flat annular surface surrounding the outer interface portion c230. The outer interface portion c230 has an outer interface face c231 at its end. The outer interface portion c230 is illustrated as having a circular cross section but again other shapes can be envisages.

Within the outer interface portion c230 is an inner interface portion c232, which here is provided as a column again projecting from the contact surface c221 of the trunk portion c220. The inner interface portion c232 is tipped with an inner interface face c233. The inner interface portion c232 and the inner interface face c233 are not visible in Figure C23.

Therefore, and in considering the cross section of this main body c120 there is provided Figure C24. This shows the main body c120 of Figure C23 from ‘above’. At an outer circumference is the annular contact surface c221, from which the outer interface portion c230 tipped with the outer interface face c231 projects. As that has a tubular shape, the contact surface c221 is visible within it. Within that is the columnar inner interface portion c232, tipped with the inner interface face c233.

In the present embodiment, the outer and inner interface faces c231, c233 are provided with electrical contacts. These contacts may be supplied with power from a source within the main body c120. When a consumable or cartridge is loaded, as explained below, these contacts connect with corresponding contacts in the cartridge to supply power to it and hence generate vapour.

Indeed, as illustrated, the entire outer and inner interface faces c231, c233 are formed as electrical contacts. This will be explained more below with reference to Figure C26.

Also visible in Figure C24 are main body magnets c240. These magnets can engage with corresponding sections on the consumable discussed below to attach the consumable to the main body c120. It will be recognised that if magnets are present on the main body c120, magnetic material can be present on the consumable instead of magnets. Similarly, the main body magnets c240 can be replaced with magnetic material if one or more magnets are present on the consumable.

The consumable c150 is illustrated in Figure C25. It includes an annular contact surface c250 sized to engage with the contact surface c221 of the main body c120. The annular contact surface c250 of the consumable c150 surrounds an interface cavity c260 shaped to receive the outer interface portion c230. On the inner surface c261 of the cavity are provided electrical contacts. The inner electrical contact c262 is positioned centrally, such that it touches the electrical contact of the inner interface face c233 when the main body c120 and consumable c150 are attached. The outer electrical contact c263 is positioned at the outer edge of the cavity c260, such that it touches the electrical contact of the outer interface face c231 when the main body c120 and consumable c150 are attached.

Also illustrated in Figure C25 are consumable or cartridge magnets c270. These are arranged on the annular contact surface c250. They are evenly spaced although clearly this is not essential. These magnets can engage with corresponding sections on the main body discussed above to attach the consumable c150 to the main body c120. It will be recognised that if magnets are present on the main body c120, magnetic material can be present on the consumable instead of magnets c270. Similarly, the main body magnets c240 can be replaced with magnetic material if one or more magnets c270 are present on the consumable c150.

It will be readily apparent that shape of the outer interface portion c230 of the main body c120 and the interface cavity c260 of the consumable c150 allow the rotatable engagement of the main body c120 and the consumable c150. When the two are engaged, magnetic coupling between the parts c240 on the main body and c270 on the consumable holds them in position. The magnetic link can be broken by the user with torsion on the main body c120 and/or consumable c150, and relative rotation leads to a different magnetic interaction forming and thus holding the main body c120 and consumable c150 in a different relative rotation to when they began. This is equivalent to a movement from a first position to a second position as defined herein.

A cavity/projection interface is preferable as it can allow free turning or spinning of the consumable and main body with respect to one another. The is particularly the case where a circular cross section is chosen for the projection and the corresponding cavity.

Because of the positioning of the electrical contacts, contact is maintained during this rotational operation. Accordingly the user may benefit from an uninterrupted operation of the smoking substitute system, while transitioning from a first operating condition to a second operating condition.

From the number of magnetic parts provided in this embodiment, it can be seen that six unique rotational relationships can be held by the magnets. Accordingly in this embodiment there may be six positions and six operating conditions between which the user can select. Of course each of these operating conditions may be unique, or there may be some duplication. With the magnetic forces at work the main body and consumable will ‘snap’ to the nearest held position, although of course ring-like magnets can be envisaged, along with other engagement means, to give a variety of different positional options.

Similarly, while a magnetic or any other engagement means can be used to attach the main body c120 to the consumable c150, the ‘indexing’ or definition of various operational rotational positions is not necessarily also done by the magnets. For example, the main body and consumable/cartridge may comprise a series of corresponding convex and concave portions, which correspond only in certain rotational alignments, to define first, second and further positions. The main body may have the concave portions, or the convex portions, or a mixture of both. The corresponding portions are provided on the consumable.

Those portions could, for example, be in the positions shown for magnetic parts c240 and c270 in Figures C24-C26. In such a case, for example, the annular contact faces c221 and c250 could be magnetic to provide a force to hold the main body c120 and the consumable c150 together.

Figure C26 shows the smoking substitute system with the main body c120 and the consumable cartridge c150 engaged. Here the fit between the outer interface portion c230 and the cavity c260 can be seen, along with the engagement between inner interface face c233 and inner electrical contact c262, and between outer interface face c231 and outer electrical contact c263.

Relative rotation of the main body c120 and the consumable c150 moves the relative positions of the engagement magnetic parts c240, c270 to different configurations. It moves the position of the inner and outer electrical contacts c262, c263 on the surface of the inner interface face c233 and outer interface face c231. This alters the operation condition of the smoking substitute system. For example the position of the outer electrical contact c263 on the surface of the outer interface face c263 may alter the resistance in the power circuit, and thereby lead to a different power being supplied to the consumable in different rotational positions.

It can easily be envisaged how other properties can be controlled in this way, for example activation or deactivation of circuits to particular reservoirs (impacting flavour, strength or flow of vapour; turning flavours on or off; changing the amount of flavour delivered; changing the amount of nicotine delivered; and so on); opening or adjusting of air flow channels (impacting particle size and so on), or simply to engage or disengage power flow to the device.

A further example is illustrated in Figure C27. In this embodiment, the outer wall of the consumable c150 is provided with an air inlet hole c280 (see Figure C27(a), (e), (f)). The outer wall of the outer interface portion c230 of the main body c120 is provided with a series of through holes c290 of different sizes (here, three: see Figure C27(b), (c), (d)). Those through holes lead to the space between the outer interface portion c230 and the inner interface portion c232. That space can form part of the air passage to the outlet for vapour inhalation by the user.

By rotation between three different positions, the air inlet hole c280 can be aligned with different ones of the through holes c290. This has the effect of increasing or decreasing the effective size of the inlet into the device, altering the amount and properties of air flow with the effects described herein. The three positions aligning the air inlet hole with one of the three through holes c290 therefore cause the smoking substitute system to operate in three different operating conditions.

Of course it will be seen that in an alternative embodiment there may instead be provided a single through hole c290, and a series of air inlet holes c280 of varying sizes on the outer wall of the consumable c150. Indeed this may be preferred, allowing the air flow options to be tailored to the particular liquid aerosol precursor(s) contained within a given consumable.

There now follows a disclosure of certain experimental work undertaken to determine the effects of certain conditions in the smoking substitute apparatus on the particle size of the generated aerosol.

The experimental results reported here are relevant to the embodiments disclosed above in view of their demonstration of the control over particle size based on control of the conditions at the wick. In particular, the embodiments disclosed above have an effect on the air flow conditions and/or temperature in the vaporisation chamber, in view of the reduction in air flow velocity in the upstream portion of the air flow path for a given air flow rate.

1. Introduction

Aerosol droplet size is a considered to be an important characteristic for smoking substitution devices. Droplets in the range of 2-5 μm are preferred in order to achieve improved nicotine delivery efficiency and to minimise the hazard of second-hand smoking. However, at the time of writing (September 2019), commercial EVP devices typically deliver aerosols with droplet size averaged around 0.5 μm, and to the knowledge of the inventors not a single commercially available device can deliver an aerosol with an average particle size exceeding 1 μm.

The present inventors speculate, without themselves wishing to be bound by theory, that there has to date been a lack of understanding in the mechanisms of e-liquid evaporation, nucleation and droplet growth in the context of aerosol generation in smoking substitute devices. The present inventors have therefore studied these issues in order to provide insight into mechanisms for the generation of aerosols with larger particles. The present inventors have carried out experimental and modelling work alongside theoretical investigations, leading to significant achievements as now reported.

This disclosure considers the roles of air velocity, air turbulence and vapour cooling rate in affecting aerosol particle size.

2. Experiments

In this work, a Malvern PANalytical Spraytec laser diffraction system was employed for the particle size measurement. In order to limit the number of variables, the same coil and wick (1.5 ohms Ni—Cr coil, 1.8 mm Y07 cotton wick), the same e-liquid (1.6% freebase nicotine, 65:35 propylene glycol (PG)/vegetable glycerine (VG) ratio, no added flavour) and the same input power (10 W) were used in all experiments. Y07 represents the grade of cotton wick, meaning that the cotton has a linear density of 0.7 grams per meter.

Particle sizes were measured in accordance with ISO 13320:2009(E), which is an international standard on laser diffraction methods for particle size analysis. This is particularly well suited to aerosols, because there is an assumption in this standard that the particles are spherical (which is a good assumption for liquid-based aerosols). The standard is stated to be suitable for particle sizes in the range 0.1 micron to 3 mm.

The results presented here concentrate on the volume-based median particle size Dv50. This is to be taken to be the same as the parameter d₅₀ used above.

2.1. Rectangular Tube Testing

The work reported here based on the inventors' insight that aerosol particle size might be related to: 1) air velocity; 2) flow rate; and 3) Reynolds number. In a given EVP device, these three parameters are inter-linked to each other, making it difficult to draw conclusions on the roles of each individual factor. In order to decouple these factors, experiments were carried out using a set of rectangular tubes having different dimensions. These were manufactured by 3D printing. The rectangular tubes were 3D printed in an MJP 2500 3D printer. FIG. 1 illustrates the set of rectangular tubes. Each tube has the same depth and length but different width. Each tube has an integral end plate in order to provide a seal against air flow outside the tube. Each tube also has holes formed in opposing side walls in order to accommodate a wick.

FIG. 2 shows a schematic perspective longitudinal cross sectional view of an example rectangular tube 1170 with a wick 1162 and heater coil 1164 installed. The location of the wick is about half way along the length of the tube. This is intended to allow the flow of air along the tube to settle before reaching the wick.

FIG. 3 shows a schematic transverse cross sectional view an example rectangular tube 1170 with a wick 1162 and heater coil 1164 installed. In this example, the internal width of the tube is 12 mm

The rectangular tubes were manufactured to have same internal depth of 6 mm in order to accommodate the standardized coil and wick, however the tube internal width varied from 4.5 mm to 50 mm. In this disclosure, the “tube size” is referred to as the internal width of rectangular tubes.

The rectangular tubes with different dimensions were used to generate aerosols that were tested for particle size in a Malvern PANalytical Spraytec laser diffraction system. An external digital power supply was dialed to 2.6 A constant current to supply 10 W power to the heater coil in all experiments. Between two runs, the wick was saturated manually by applying one drop of e-liquid on each side of the wick.

Three groups of experiments were carried out in this study:

-   -   1. 1.3 lpm (litres per minute, L min⁻¹ or LPM) constant flow         rate on different size tubes     -   2. 2.0 lpm constant flow rate on different size tubes     -   3. 1 m/s constant air velocity on 3 tubes: i) 5 mm tube at 1.4         lpm flow rate; ii) 8 mm tube at 2.8 lpm flow rate; and iii) 20         mm tube at 8.6 lpm flow rate.

Table 1 shows a list of experiments in this study. The values in “calculated air velocity” column were obtained by simply dividing the flow rate by the intersection area at the centre plane of wick. Reynolds numbers (Re) were calculated through the following equation:

${Re} = \frac{\rho{vL}}{\mu}$

where: ρ is the density of air (1.225 kg/m³); ν is the calculated air velocity in table 1; μ is the viscosity of air (1.48×10⁻⁵ m²/s); L is the characteristic length calculated by:

$L = \frac{4P}{A}$

where: P is the perimeter of the flow path's intersection, and A is the area of the flow path's intersection.

TABLE 1 List of experiments in the rectangular tube study Calculated air Tube size Flow rate Reynolds velocity [mm] [lpm] number [m/s] 1.3 lpm 4.5 1.3 153 1.17 constant 6 1.3 142 0.71 flow rate 7 1.3 136 0.56 8 1.3 130 0.47 10 1.3 120 0.35 12 1.3 111 0.28 20 1.3 86 0.15 50 1.3 47 0.06 2.0 lpm 4.5 2.0 236 1.81 constant 5 2.0 230 1.48 flow rate 6 2.0 219 1.09 8 2.0 200 0.72 12 2.0 171 0.42 20 2.0 132 0.23 50 2.0 72 0.09 1.0 m/s 5.0 1.4 155 1.00 constant air 8 2.8 279 1.00 velocity 20 8.6 566 1.00

Five repetition runs were carried out for each tube size and flow rate combination. Between adjacent runs there were at least 5 minutes wait time for the Spraytec system to be purged. In each run, real time particle size distributions were measured in the Spraytec laser diffraction system at a sampling rate of 2500 per second, the volume distribution median (Dv50) was averaged over a puff duration of 4 seconds. Measurement results were averaged and the standard deviations were calculated to indicate errors as shown in section 4 below.

2.2. Turbulence Tube Testing

The Reynolds numbers in Table 1 are all well below 1000, therefore, it is considered fair to assume all the experiments in section 2.1 would be under conditions of laminar flow. Further experiments were carried out and reported in this section to investigate the role of turbulence.

Turbulence intensity was introduced as a quantitative parameter to assess the level of turbulence. The definition and simulation of turbulence intensity is discussed below (see section 3.2).

Different device designs were considered in order to introduce turbulence. In the experiments reported here, jetting panels were added in the existing 12 mm rectangular tubes upstream of the wick. This approach enables direct comparison between different devices as they all have highly similar geometry, with turbulence intensity being the only variable.

FIGS. 4A-4D show air flow streamlines in the four devices used in this turbulence study. FIG. 4A is a standard 12 mm rectangular tube with wick and coil installed as explained in the previous section, with no jetting panel. FIG. 4B has a jetting panel located 10 mm below (upstream from) the wick. FIG. 4C has the same jetting panel 5 mm below the wick. FIG. 4D has the same jetting panel 2.5 mm below the wick. As can be seen from FIGS. 4B-4D, the jetting panel has an arrangement of apertures shaped and directed in order to promote jetting from the downstream face of the panel and therefore to promote turbulent flow. Accordingly, the jetting panel can introduce turbulence downstream, and the panel causes higher level of turbulence near the wick when it is positioned closer to the wick. As shown in FIGS. 4A-4D, the four geometries gave turbulence intensities of 0.55%, 0.77%, 1.06% and 1.34%, respectively, with FIG. 4A being the least turbulent, and FIG. 4D being the most turbulent.

For each of FIGS. 4A-4D, there are shown three modelling images. The image on the left shows the original image (colour in the original), the central image shows a greyscale version of the image and the right hand image shows a black and white version of the image. As will be appreciated, each version of the image highlights slightly different features of the flow. Together, they give a reasonable picture of the flow conditions at the wick.

These four devices were operated to generate aerosols following the procedure explained above (section 2.1) using a flow rate of 1.3 lpm and the generated aerosols were tested for particle size in the Spraytec laser diffraction system.

2.3. High Temperature Testing

This experiment aimed to investigate the influence of inflow air temperature on aerosol particle size, in order to investigate the effect of vapour cooling rate on aerosol generation.

The experimental set up is shown in FIG. 5 . The testing used a Carbolite Gero EHA 12300B tube furnace 3210 with a quartz tube 3220 to heat up the air. Hot air in the tube furnace was then led into a transparent housing 3158 that contains the EVP device 3150 to be tested. A thermocouple meter 3410 was used to assess the temperature of the air pulled into the EVP device. Once the EVP device was activated, the aerosol was pulled into the Spraytec laser diffraction system 3310 via a silicone connector 3320 for particle size measurement.

Three smoking substitute apparatuses (referred to as “pods”) were tested in the study: pod 1 is the commercially available “myblu optimised” pod (FIG. 6 ); pod 2 is a pod featuring an extended inflow path upstream of the wick (FIG. 7 ); and pod 3 is pod with the wick located in a stagnant vaporisation chamber and the inlet air bypassing the vaporisation chamber but entraining the vapour from an outlet of the vaporisation chamber (FIGS. 8A and 8B).

Pod 1, shown in longitudinal cross sectional view (in the width plane) in FIG. 6 , has a main housing that defines a tank 160 x holding an e-liquid aerosol precursor. Mouthpiece 154 x is formed at the upper part of the pod. Electrical contacts 156 x are formed at the lower end of the pod. Wick 162 x is held in a vaporisation chamber. The air flow direction is shown using arrows.

Pod 2, shown in longitudinal cross sectional view (in the width plane) in FIG. 7 , has a main housing that defines a tank 160 y holding an e-liquid aerosol precursor. Mouthpiece 154 y is formed at the upper part of the pod. Electrical contacts 156 y are formed at the lower end of the pod. Wick 162 y is held in a vaporisation chamber. The air flow direction is shown using arrows. Pod 2 has an extended inflow path (plenum chamber 157 y) with a flow conditioning element 159 y, configured to promote reduced turbulence at the wick 162 y.

FIG. 8A shows a schematic longitudinal cross sectional view of pod 3. FIG. 8B shows a schematic longitudinal cross sectional view of the same pod 3 in a direction orthogonal to the view taken in FIG. 8A. Pod 3 has a main housing that defines a tank 160 z holding an e-liquid aerosol precursor. Mouthpiece 154 z is formed at the upper part of the pod. Electrical contacts 156 z are formed at the lower end of the pod. Wick 162 z is held in a vaporisation chamber. The air flow direction is shown using arrows. Pod 3 uses a stagnant vaporiser chamber, with the air inlets bypassing the wick and picking up the vapour/aerosol downstream of the wick.

All three pods were filled with the same e-liquid (1.6% freebase nicotine, 65:35 PG/VG ratio, no added flavour). Three experiments were carried out for each pod: 1) standard measurement in ambient temperature; 2) only the inlet air was heated to 50° C.; and 3) both the inlet air and the pods were heated to 50° C. Five repetition runs were carried out for each experiment and the Dv50 results were taken and averaged.

3. Modelling Work

In this study, modelling work was performed using COMSOL Multiphysics 5.4, engaged physics include: 1) laminar single-phase flow; 2) turbulent single-phase flow; 3) laminar two-phase flow; 4) heat transfer in fluids; and (5) particle tracing. Data analysis and data visualisation were mostly completed in MATLAB R2019a.

3.1. Velocity Modelling

Air velocity in the vicinity of the wick is believed to play an important role in affecting particle size. In section 2.1, the air velocity was calculated by dividing the flow rate by the intersection area, which is referred to as “calculated velocity” in this work. This involves a very crude simplification that assumes velocity distribution to be homogeneous across the intersection area.

In order to increase reliability of the work, computational fluid dynamics (CFD) modelling was performed to obtain more accurate velocity values:

-   -   1) The average velocity in the vicinity of the wick (defined as         a volume from the wick surface to 1 mm away from the wick         surface)     -   2) The maximum velocity in the vicinity of the wick (defined as         a volume from the wick surface to 1 mm away from the wick         surface)

TABLE 2 Average and maximum velocity in the vicinity of wick surface obtained from CFD modelling Calculated Average Maximum Tube size Flow rate velocity* velocity** Velocity** [mm] [lpm] [m/s] [m/s] [m/s] 1.3 lpm 4.5 1.3 1.17 0.99 1.80 constant 6 1.3 0.71 0.66 1.22 flow rate 7 1.3 0.56 0.54 1.01 8 1.3 0.47 0.46 0.86 10 1.3 0.35 0.35 0.66 12 1.3 0.28 0.27 0.54 20 1.3 0.15 0.15 0.32 50 1.3 0.06 0.05 0.12 2.0 lpm 4.5 2.0 1.81 1.52 2.73 constant 5 2.0 1.48 1.31 2.39 flow rate 6 2.0 1.09 1.02 1.87 8 2.0 0.72 0.71 1.31 12 2.0 0.42 0.44 0.83 20 2.0 0.23 0.24 0.49 50 2.0 0.09 0.08 0.19 *Calculated by dividing flow rate with intersection area **Obtained from CFD modelling

The CFD model uses a laminar single-phase flow setup. For each experiment, the outlet was configured to a corresponding flowrate, the inlet was configured to be pressure-controlled, the wall conditions were set as “no slip”. A 1 mm wide ring-shaped domain (wick vicinity) was created around the wick surface, and domain probes were implemented to assess the average and maximum magnitudes of velocity in this ring-shaped wick vicinity domain.

The CFD model outputs the average velocity and maximum velocity in the vicinity of the wick for each set of experiments carried out in section 2.1. The outcomes are reported in Table 2.

3.2. Turbulence Modelling

Turbulence intensity (I) is a quantitative value that represents the level of turbulence in a fluid flow system. It is defined as the ratio between the root-mean-square of velocity fluctuations, u′, and the Reynolds-averaged mean flow velocity,

${U:I} = {\frac{u^{\prime}}{U} = {\frac{\sqrt{\frac{1}{3}\left( {u_{x}^{\prime 2} + u_{y}^{\prime 2} + u_{z}^{\prime 2}} \right)}}{\sqrt{{\overset{\_}{u}}_{x}^{2} + {\overset{\_}{u}}_{y}^{2} + {\overset{\_}{u}}_{z}^{2}}} = \frac{\sqrt{\frac{1}{3}\left\lbrack {\left( {u_{x} - \overset{\_}{u_{x}}} \right)^{2} + {{\left( {u_{y} - \overset{\_}{u_{y}}} \right)^{2}++}\left( {u_{z} - \overset{\_}{u_{z}}} \right)^{2}}} \right\rbrack}}{\sqrt{{\overset{\_}{u}}_{x}^{2} + {\overset{\_}{u}}_{y}^{2} + {\overset{\_}{u}}_{z}^{2}}}}}$

where u_(x), u_(y) and u_(z) are the x-, y- and z-components of the velocity vector, u_(x) , u_(y) , and u_(z) represent the average velocities along three directions.

Higher turbulence intensity values represent higher levels of turbulence. As a rule of thumb, turbulence intensity below 1% represents a low-turbulence case, turbulence intensity between 1% and 5% represents a medium-turbulence case, and turbulence intensity above 5% represents a high-turbulence case.

In this study, turbulence intensity was obtained from CFD simulation using turbulent single-phase setup in COMSOL Multiphysics. For each of the four experiments explained in section 2.2, the outlet was set to 1.3 lpm, the inlet was set to be pressure-controlled, and all wall conditions were set to be “no slip”.

Turbulence intensity was assessed within the volume up to 1 mm away from the wick surface (defined as the wick vicinity domain). For the four experiments explained in section 2.2, the turbulence intensities are 0.55%, 0.77%, 1.06% and 1.34%, respectively, as also shown in FIGS. 4A-4D.

3.3. Cooling Rate Modelling

The cooling rate modelling involves three coupling models in COMSOL Multiphysics: 1) laminar two-phase flow; 2) heat transfer in fluids, and 3) particle tracing. The model is setup in three steps:

1) Set Up Two Phase Flow Model

Laminar mixture flow physics was selected in this study. The outlet was configured in the same way as in section 3.1. However, this model includes two fluid phases released from two separate inlets: the first one is the vapour released from wick surface, at an initial velocity of 2.84 cm/s (calculated based on 5 mg total particulate mass over 3 seconds puff duration) with initial velocity direction normal to the wick surface; the second inlet is air influx from the base of tube, the rate of which is pressure-controlled.

2) Set Up Two-Way Coupling with Heat Transfer Physics

The inflow and outflow settings in heat transfer physics was configured in the same way as in the two-phase flow model. The air inflow was set to 25° C., and the vapour inflow was set to 209° C. (boiling temperature of the e-liquid formulation). In the end, the heat transfer physics is configured to be two-way coupled with the laminar mixture flow physics. The above model reaches steady state after approximately 0.2 second with a step size of 0.001 second.

3) Set Up Particle Tracing

A wave of 2000 particles were release from wick surface at t=0.3 second after the two-phase flow and heat transfer model has stabilised. The particle tracing physics has one-way coupling with the previous model, which means the fluid flow exerts dragging force on the particles, whereas the particles do not exert counterforce on the fluid flow. Therefore, the particles function as moving probes to output vapour temperature at each timestep.

The model outputs average vapour temperature at each time steps. A MATLAB script was then created to find the time step when the vapour cools to a target temperature (50° C. or 75° C.), based on which the vapour cooling rates were obtained (Table 3).

TABLE 3 Average vapour cooling rate obtained from Multiphysics modelling Cooling rate to Cooling rate to Tube size Flow rate 50° C. 75° C. [mm] [lpm] [° C./ms] [° C./ms] 1.3 lpm 4.5 1.3 11.4  44.7 constant 6 1.3 5.48 14.9 flow rate 7 1.3 3.46 7.88 8 1.3 2.24 5.15 10 1.3 1.31 2.85 12 1.3  0.841 1.81 20 1.3 0*   0.536 50 1.3 0   0 2.0 lpm 4.5 2.0 19.9  670 constant 5 2.0 13.3  67 flow rate 6 2.0 8.83 26.8 8 2.0 3.61 8.93 12 2.0 1.45 3.19 20 2.0  0.395 0.761 50 2.0 0   0 *Zero cooling rate when the average vapour temperature is still above target temperature after 0.5 second

4. Results and Discussions

Particle size measurement results for the rectangular tube testing are shown in Table 4. For every tube size and flow rate combination, five repetition runs were carried out in the Spraytec laser diffraction system. The Dv50 values from five repetition runs were averaged, and the standard deviations were calculated to indicate errors, as shown in Table 4.

In this section, the roles of different factors affecting aerosol particle size will be discussed based on experimental and modelling results.

TABLE 4 Particle size measurement results for the rectangular tube testing Dv50 standard Tube size Flow rate Dv50 average deviation [mm] [lpm] [μm] [μm] 1.3 lpm 4.5 1.3 0.971 0.125 constant 6 1.3 1.697 0.341 flow rate 7 1.3 2.570 0.237 8 1.3 2.705 0.207 10 1.3 2.783 0.184 12 1.3 3.051 0.325 20 1.3 3.116 0.354 50 1.3 3.161 0.157 2.0 lpm 4.5 2.0 0.568 0.039 constant 5 2.0 0.967 0.315 flow rate 6 2.0 1.541 0.272 8 2.0 1.646 0.363 12 2.0 3.062 0.153 20 2.0 3.566 0.260 50 2.0 3.082 0.440 1.0 m/s 5.0 1.4 1.302 0.187 constant air 8 2.8 1.303 0.468 velocity 20 8.6 1.463 0.413

4.1. Decouple the Factors Affecting Particle Size

The particle size (Dv50) experimental results are plotted against calculated air velocity in FIG. 9 . The graph shows a strong correlation between particle size and air velocity.

Different size tubes were tested at two flow rates: 1.3 lpm and 2.0 lpm. Both groups of data show the same trend that slower air velocity leads to larger particle size. The conclusion was made more convincing by the fact that these two groups of data overlap well in FIG. 9 : for example, the 6 mm tube delivered an average Dv50 of 1.697 μm when tested at 1.3 lpm flow rate, and the 8 mm tube delivered a highly similar average Dv50 of 1.646 μm when tested at 2.0 lpm flow rate, as they have similar air velocity of 0.71 and 0.72 m/s, respectively.

In addition, FIG. 10 shows the results of three experiments with highly different setup arrangements: 1) 5 mm tube measured at 1.4 lpm flow rate with Reynolds number of 155; 2) 8 mm tube measured at 2.8 lpm flow rate with Reynolds number of 279; and 3) 20 mm tube measured at 8.6 lpm flow rate with Reynolds number of 566. It is relevant that these setup arrangements have one similarity: the air velocities are all calculated to be 1 m/s. FIG. 10 shows that, although these three sets of experiments have different tube sizes, flow rates and Reynolds numbers, they all delivered similar particle sizes, as the air velocity was kept constant. These three data points were also plotted out in FIG. 9 (1 m/s data with star marks) and they tie in nicely into particle size-air velocity trendline.

The above results lead to a strong conclusion that air velocity is an important factor affecting the particle size of EVP devices. Relatively large particles are generated when the air travels with slower velocity around the wick. It can also be concluded that flow rate, tube size and Reynolds number are not necessarily independently relevant to particle size, providing the air velocity is controlled in the vicinity of the wick.

4.2. Further Consideration of Velocity

In FIG. 9 the “calculated velocity” was obtained by dividing the flow rate by the intersection area, which is a crude simplification that assumes a uniform velocity field. In order to increase reliability of the work, CFD modelling has been performed to assess the average and maximum velocities in the vicinity of the wick. In this study, the “vicinity” was defined as a volume from the wick surface up to 1 mm away from the wick surface.

The particle size measurement data were plotted against the average velocity (FIG. 11 ) and maximum velocity (FIG. 12 ) in the vicinity of the wick, as obtained from CFD modelling.

The data in these two graphs indicates that in order to obtain an aerosol with Dv50 larger than 1 μm, the average velocity should be less than or equal to 1.2 m/s in the vicinity of the wick and the maximum velocity should be less than or equal to 2.0 m/s in the vicinity of the wick.

Furthermore, in order to obtain an aerosol with Dv50 of 2 μm or larger, the average velocity should be less than or equal to 0.6 m/s in the vicinity of the wick and the maximum velocity should be less than or equal to 1.2 m/s in the vicinity of the wick.

It is considered that typical commercial EVP devices deliver aerosols with Dv50 around 0.5 μm, and there is no commercially available device that can deliver aerosol with Dv50 exceeding 1 μm. It is considered that typical commercial EVP devices have average velocity of 1.5-2.0 m/s in the vicinity of the wick.

4.3. The Role of Turbulence

The role of turbulence has been investigated in terms of turbulence intensity, which is a quantitative characteristic that indicates the level of turbulence. In this work, four tubes of different turbulence intensities were used to general aerosols which were measured in the Spraytec laser diffraction system. The particle size (Dv50) experimental results are plotted against turbulence intensity in FIG. 13 .

The graph suggests a correlation between particle size and turbulence intensity, that lower turbulence intensity is beneficial for obtaining larger particle size. It is noted that when turbulence intensity is above 1% (medium-turbulence case), there are relatively large measurement fluctuations. In FIG. 13 , the tube with a jetting panel 10 mm below the wick has the largest error bar, because air jets become unpredictable near the wick after traveling through a long distance.

The results clearly indicate that laminar air flow is favourable for the generation of aerosols with larger particles, and that the generation of large particle sizes is jeopardised by introducing turbulence. In FIG. 13 , the 12 mm standard rectangular tube (without jetting panel) delivers above 3 μm particle size (Dv50). The particle size values reduced by at least a half when jetting panels were added to introduce turbulence.

4.4. Vapour Cooling Rate

FIG. 14 shows the high temperature testing results. Larger particle sizes were observed from all 3 pods when the temperature of inlet air increased from room temperature (23° C.) to 50° C. When the pods were heated as well, two of the three pods saw even larger particle size measurement results, while pod 2 was unable to be measured due to significant amount of leakage.

Without wishing to be bound by theory, the results are in line with the inventors' insight that control over the vapour cooling rate provides an important degree of control over the particle size of the aerosol. As reported above, the use of a slow air velocity can have the result of the formation of an aerosol with large Dv50. It is considered that this is due to slower air velocity allowing a slower cooling rate of the vapour.

Another conclusion related to laminar flow can also be explained by a cooling rate theory: laminar flow allows slow and gradual mixing between cold air and hot vapour, which means the vapour can cool down in slower rate when the airflow is laminar, resulting in larger particle size.

The results in FIG. 14 further validate this cooling rate theory: when the inlet air has higher temperature, the temperature difference between hot vapour and cold air becomes smaller, which allows the vapour to cool down at a slower rate, resulting in larger particle size; when the pods were heated as well, this mechanism was exaggerated even more, leading to an even slower cooling rate and an even larger particle size.

4.5. Further Consideration of Vapour Cooling Rate

In section 3.3, the vapour cooling rates for each tube size and flow rate combination were obtained via multiphysics simulation. In FIG. 15 and FIG. 16 , the particle size measurement results were plotted against vapour cooling rate to 50° C. and 75° C., respectively.

The data in these graphs indicates that in order to obtain an aerosol with Dv50 larger than 1 μm, the apparatus should be operable to require more than 16 ms for the vapour to cool to 50° C., or an equivalent (simplified to an assumed linear) cooling rate being slower than 10° C./ms. From an alternative viewpoint, in order to obtain an aerosol with Dv50 larger than 1 μm, the apparatus should be operable to require more than 4.5 ms for the vapour to cool to 75° C., or an equivalent (simplified to an assumed linear) cooling rate slower than 30° C./ms.

Furthermore, in order to obtain an aerosol with Dv50 of 2 μm or larger, the apparatus should be operable to require more than 32 ms for the vapour to cool to 50° C., or an equivalent (simplified to an assumed linear) cooling rate being slower than 5° C./ms. From an alternative viewpoint, in order to obtain an aerosol with Dv50 of 2 μm or larger, the apparatus should be operable to require more than 13 ms for the vapour to cool to 75° C., or an equivalent (simplified to an assumed linear) cooling rate slower than 10° C./ms.

5. Conclusions of Particle Size Experimental Work

In this work, particle size (Dv50) of aerosols generated in a set of rectangular tubes was studied in order to decouple different factors (flow rate, air velocity, Reynolds number, tube size) affecting aerosol particle size. It is considered that air velocity is an important factor affecting particle size—slower air velocity leads to larger particle size. When air velocity was kept constant, the other factors (flow rate, Reynolds number, tube size) has low influence on particle size.

The role of turbulence was also investigated. It is considered that laminar air flow favours generation of large particles, and introducing turbulence deteriorates (reduces) the particle size.

Modelling methods were used to simulate the average air velocity, the maximum air velocity, and the turbulence intensity in the vicinity of the wick. A COMSOL model with three coupled physics has also been developed to obtain the vapour cooling rate.

All experimental and modelling results support a cooling rate theory that slower vapour cooling rate is a significant factor in ensuring larger particle size. Slower air velocity, laminar air flow and higher inlet air temperature lead to larger particle size, because they all allow vapour to cool down at slower rates.

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means, for example, +/−10%.

The words “preferred” and “preferably” are used herein refer to embodiments of the invention that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims.

In the following numbered “clauses” are set out statements of broad combinations of novel and inventive features of the present invention herein disclosed.

Development A

[ME Ref: 7624570; Nerudia Ref: P01221]

A1. A smoking substitute apparatus comprising:

an air inlet;

an outlet;

an aerosol generator for generating an aerosol from an aerosol precursor for inhalation by a user, the aerosol generator comprising a heating element;

an air flow path between the air inlet and the outlet for conveying the aerosol to the user;

an upstream portion of the air flow path being disposed between the air inlet and the aerosol generator, the upstream portion being defined at least in part by an inner wall of the apparatus, the inner wall being formed from plastics material by moulding;

one or more electrical connectors for electrically connecting the heating element to a power source; wherein the one or more electrical connectors are at least partially moulded into, and extend along, the inner wall of the upstream portion of the air flow path.

A2. A smoking substitute apparatus according to clause A1 wherein the electrical conductor has a length direction substantially parallel to the air flow direction along the air flow path in the upstream portion and, along the length of the electrical connector, some parts of the length are moulded, or partially moulded, into the inner wall of the upstream portion of the air flow path.

A3. A smoking substitute apparatus according to clause A2 wherein other parts of the electrical connector, corresponding to one of more parts between the parts of the length that are moulded into the inner wall, abut the inner wall.

A4. A smoking substitute apparatus according to clause A1 wherein the electrical conductor has a length direction substantially parallel to the air flow direction along the air flow path in the upstream portion and a width direction corresponding to a circumferential direction of the upstream portion of the air flow path, perpendicular to the length direction, and a depth direction corresponding to a radial direction of the upstream portion of the air flow path, perpendicular to both the length direction and the circumferential direction, wherein the width of the electrical connector varies along its length.

A5. A smoking substitute apparatus according to clause A4 wherein the electrical connector has wide portions at which the electrical connectors is moulded or partially moulded to the inner wall of the upstream portion, the inner wall being moulded into an aperture formed in the wide portion.

A6. A smoking substitute apparatus according to any one of clauses A1 to A5 wherein an aspect ratio of the electrical connector, defined as width/depth, is not less than 4.

A7. A smoking substitute apparatus according to any one of clauses A1 to A6 wherein the electrical connector is partially moulded into the inner wall along the length of the electrical connector in the upstream portion of the air flow path such that a proportion of the depth of the electrical connector is moulded into the inner wall, this proportion being at least 30%.

A8. A smoking substitute apparatus according to any one of clauses A1 to A6 wherein the electrical connector is fully moulded into the inner wall of the upstream portion of the air flow path.

A9. A smoking substitute system comprising a smoking substitute apparatus according to any one of clauses A1 to A8 and a main body, the main body comprising a power source, the smoking substitute apparatus and the main body being engageable together to form the smoking substitute system.

A10. A method of operating a smoking substitute apparatus according to any one of clauses A1 to A8 in which air is drawn through the apparatus at an air flow rate in the range 1.3-2.0 L/min and the aerosol generator operated to produce an aerosol with Dv50 in the range 2-5 μm.

Development B

[ME Ref: 7623218; Nerudia Ref: P01205]

B1. A smoking substitute apparatus for engagement with a main body to provide a smoking substitute system, the smoking substitute apparatus comprising:

at least two air inlets;

an aerosol generator for generating an aerosol from an aerosol precursor for inhalation by a user;

an outlet;

at least one air flow path between the air inlet and the outlet for conveying the aerosol to the user;

an occlusion member being selectively configurable between a first configuration in which a first one of said at least two air inlets is covered and a second configuration in which the said first one of the at least two air inlets is uncovered;

wherein the first configuration is selectable by the user based on a first engagement arrangement between the smoking substitute apparatus and the main body, and the second configuration is selectable by the user based on a second engagement arrangement between the smoking substitute apparatus and the main body.

B2. The smoking substitute apparatus according to clause B1, wherein the occlusion member is biased towards the second configuration.

B3. The smoking substitute apparatus according to clause B2, wherein the occlusion member is a deformable plate.

B4. The smoking substitute apparatus according to any one of clauses B1 to B3, wherein the occlusion member is arranged such that when the user pushes the smoking substitute apparatus towards the main body, the occlusion member is forced into the first configuration.

B5. The smoking substitute apparatus according to any one of clauses B1 to B4, wherein the apparatus further comprises a minimum configuration distance corresponding to a difference in relative position between the smoking substitute apparatus and the main body for the first engagement arrangement and for the second engagement arrangement.

B6. The smoking substitute apparatus according to any one of clauses B1 to B5, wherein the apparatus provides the user with a haptic indication of reaching the first and/or second engagement arrangement.

B7. A smoking substitute apparatus according to any one of clauses B1 to B6 wherein the aerosol generator is located in an aerosol generation chamber and, in use, at least a part of the air flow to the outlet bypasses the aerosol generation chamber.

B8. A smoking substitute apparatus according to any one of clauses B1 to B7 wherein the smoking substitute apparatus is comprised by or within a cartridge configured for engagement with a main body, the cartridge and main body together forming a smoking substitute system.

B9. A smoking substitute system comprising:

a main body, and a smoking substitute apparatus according to any one of clauses B1 to B8, wherein the smoking substitute apparatus is removably engageable with the main body.

B10. A smoking substitute system according to clause B9, wherein the occlusion member is arranged such that when the user pushes the smoking substitute apparatus towards the main body, the occlusion member is forced into the first configuration by pressing against a protrusion provided in the main body.

B11. A method of using a smoking substitute apparatus including the step of engaging the smoking substitute apparatus with a main body to provide a smoking substitute system, the smoking substitute apparatus comprising:

at least two air inlets;

an aerosol generator for generating an aerosol from an aerosol precursor for inhalation by a user; an outlet;

at least one air flow path between the air inlet and the outlet for conveying the aerosol to the user; and an occlusion member;

wherein the method further comprises the steps of selectively configuring the occlusion member between:

(i) a first configuration in which a first one of the at least two air inlets is covered, wherein the first configuration is selected by the user based on a first engagement arrangement between the smoking substitute apparatus and the main body, and

(ii) a second configuration in which the said first one of the at least two air inlets in uncovered, wherein the second configuration is selected by the user based on a second engagement arrangement between the smoking substitute apparatus and the main body.

B12. A method according to clause B11, wherein the first engagement arrangement is selected by the user pushing the smoking substitute apparatus towards the main body to configure the occlusion member into the first configuration.

B13. A method according to clause B11 or clause B12, wherein the second engagement arrangement is selected by the user, starting from the first engagement arrangement, pulling the smoking substitute apparatus at least a minimum configuration distance away from the main body to configure the occlusion member into the second configuration.

Development C

[ME Ref: 7628191; Nerudia Ref: P01210]

C1. A smoking substitute system comprising:

-   -   a main body comprising a power source for supplying power to a         vaporizer;     -   a cartridge comprising a reservoir for containing a liquid         aerosol precursor for vaporization by the vaporizer,     -   the cartridge rotatably engagable with the main body so as to be         rotatable between a first position in which the system operates         according to a first operating condition, and a second position         in which the system operates according to a second operating         condition that is different to the first operating condition.

C2. A smoking substitute system according to clause C1, wherein the cartridge is releasably engageable with the main body.

C3. A smoking substitute system according to clause C1 or clause C2, wherein either the main body or the cartridge comprises one or more retaining means which engages the other of the cartridge or the main body to hold the cartridge in the first position or the second position.

C4. A smoking substitute system according to clause C3, wherein either the main body or the cartridge comprises a first retaining means which engages the other of the cartridge or the main body to hold the cartridge in the first position; and either the main body or the cartridge comprises a second retaining means which engages the other of the cartridge or the main body to hold the cartridge in the second position.

C5. A smoking substitute system according to clause C3 or clause C4, wherein the or each retaining means comprises a magnet.

C6. A smoking substitute system according to clause C5, wherein the main body comprises a first series of magnets and the cartridge comprises a second series of magnets, whereby rotation of the cartridge with respect to the main body causes different ones of the first series of magnets and the second series of magnets to engage.

C7. A smoking substitute system according to any one of the preceding clauses C1 to C6, wherein the first operating condition and the second operating condition differ by the amount, identity or content of the liquid aerosol precursor vaporized by the vaporizer.

C8. A smoking substitute system according to any one of the preceding clauses C1 to C7, wherein the first operating condition and the second operating condition differ by the amount of power supplied to the vaporizer.

C9. A smoking substitute system according to any one of the preceding clauses C1 to C8, comprising an air inlet, an outlet, and at least one air flow path between the air inlet and the outlet for conveying vaporized liquid aerosol precursor to the user;

-   -   the first operating condition and the second operating condition         having different air flow between the air inlet and the outlet.

C10. A smoking substitute system according to clause 8, wherein the first operating condition and the second operating condition differ by the size of the air inlet.

C11. A smoking substitute system according to clause 8 or clause 9, wherein the first operating condition and the second operating condition differ by the length, shape or cross-section of the air flow path.

C12. A smoking substitute system according to any one of the preceding clauses C1 to C11, wherein the cartridge comprises a first reservoir for containing a first liquid aerosol precursor for vaporization by the vaporizer and a second reservoir for containing a second liquid aerosol precursor for vaporization by the vaporizer;

-   -   and wherein in the first operating condition the first liquid         aerosol precursor is vaporized by the vaporizer and in the         second operating condition the second liquid aerosol precursor         is vaporized by the vaporizer.

C13. A smoking substitute apparatus comprising a reservoir for containing a liquid aerosol precursor for vaporization by a vaporizer; the smoking substitute apparatus having a retaining means for engaging a main body in a first position or a second position;

-   -   the smoking substitute apparatus having at least one part         selectively configurable between a first configuration and a         second configuration, the first and second configurations being         different from one another;     -   wherein the first configuration is selectable by the user based         on arrangement of the smoking substitute apparatus and the main         body in the first position, and the second configuration is         selectable by the user based on arrangement of the smoking         substitute apparatus and the main body in the second position.

C14. A smoking substitute apparatus according to clause 13, wherein the smoking substitute apparatus comprises an air inlet and an outlet, and has a first air flow path between the air inlet and the outlet which is operable in the first configuration and a second air flow path between the air inlet and the outlet which is operable in the second configuration;

-   -   or wherein the smoking substitute apparatus comprises multiple         air inlets and an outlet, and has a first air flow path between         a first air inlet and the outlet which is operable in the first         configuration and a second air flow path between a second air         inlet and the outlet which is operable in the second         configuration.

C15. A smoking substitute apparatus according to clause 13, wherein the smoking substitute apparatus comprises a vaporizer which is operable under a first condition in the first configuration and operable under a second condition in the second configuration. 

1. A smoking substitute apparatus comprising: an air inlet; an outlet; an aerosol generator for generating an aerosol from an aerosol precursor for inhalation by a user, the aerosol generator comprising a heating element; an air flow path between the air inlet and the outlet for conveying the aerosol to the user; an upstream portion of the air flow path being disposed between the air inlet and the aerosol generator, the upstream portion being defined at least in part by an inner wall of the apparatus, the inner wall being formed from plastics material by moulding; one or more electrical connectors for electrically connecting the heating element to a power source; wherein the one or more electrical connectors are at least partially moulded into, and extend along, the inner wall of the upstream portion of the air flow path.
 2. A smoking substitute apparatus according to claim 1 wherein the electrical conductor has a length direction substantially parallel to the air flow direction along the air flow path in the upstream portion and, along the length of the electrical connector, some parts of the length are moulded, or partially moulded, into the inner wall of the upstream portion of the air flow path.
 3. A smoking substitute apparatus according to claim 2 wherein other parts of the electrical connector, corresponding to one of more parts between the parts of the length that are moulded into the inner wall, abut the inner wall.
 4. A smoking substitute apparatus according to claim 1 wherein the electrical conductor has a length direction substantially parallel to the air flow direction along the air flow path in the upstream portion and a width direction corresponding to a circumferential direction of the upstream portion of the air flow path, perpendicular to the length direction, and a depth direction corresponding to a radial direction of the upstream portion of the air flow path, perpendicular to both the length direction and the circumferential direction, wherein the width of the electrical connector varies along its length.
 5. A smoking substitute apparatus according to claim 4 wherein the electrical connector has wide portions at which the electrical connectors is moulded or partially moulded to the inner wall of the upstream portion, the inner wall being moulded into an aperture formed in the wide portion.
 6. A smoking substitute apparatus according to any one of claims 1 to 5 wherein an aspect ratio of the electrical connector, defined as width/depth, is not less than
 4. 7. A smoking substitute apparatus according to any one of claims 1 to 6 wherein the electrical connector is partially moulded into the inner wall along the length of the electrical connector in the upstream portion of the air flow path such that a proportion of the depth of the electrical connector is moulded into the inner wall, this proportion being at least 30%.
 8. A smoking substitute apparatus according to any one of claims 1 to 6 wherein the electrical connector is fully moulded into the inner wall of the upstream portion of the air flow path.
 9. A smoking substitute system comprising a smoking substitute apparatus according to any one of claims 1 to 8 and a main body, the main body comprising a power source, the smoking substitute apparatus and the main body being engageable together to form the smoking substitute system.
 10. A method of operating a smoking substitute apparatus according to any one of claims 1 to 8 in which air is drawn through the apparatus at an air flow rate in the range 1.3-2.0 L/min and the aerosol generator operated to produce an aerosol with Dv50 in the range 2-5 μm. 